Report of Pakistan Steel Mill

Peoples Steel Mill Internship Report
1
CONTENTS
Introduction to PSM
Mission and vision
Refractory development center
M-shop
Scrap
Electric arc furnace
Ladle furnace
Vacuum degassing
Ingot casting
Continuous casting
Forging shop (R1, R3, P1 and P2 Shops)
Bar rolling mill (Q-Shop)
Blooming and slabbing mill (N-Shop)
Water Treatment
Q.A.D. Laboratory

2
Acknowledgement
We would like to express our deepest appreciation to all
those who provided us the possibility to complete this
report. The internship opportunity we had with (PEOPLES
STEEL MILL) was a great chance for learning and
professional development. Therefore, we consider ourselves as a
very lucky individual as we were provided with an opportunity
to be a part of it. We are also grateful for having a chance to
meet so many wonderful people and professionals who led us
through this internship period.

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Introduction
Peoples steel mill Ltd. ,a world class alloy and special steel manufacturing
plant located in manghopir Karachi and spread over an area of 100 acres was
set up by the government of Pakistan in 1975 with Japanese assistance.
In order to keep pace with emerging technologies, the plant was upgraded in
1996 through a comprehensive balancing and modernization program with
the technical assistance VAIS, INTECO and Bohler of Austria. The plant is now
equipped with modern melting, refining, degassing , electro slag re-melting
and necessary casting, rolling and forging facilities with an annual capacity of
70,000 mt. The plant has the capability to produce steel according to all major
internationalquality standards and to date has manufactured more than 300
steel grades. The company produces forgings, plates, and bars in various sizes,
as well as provides after-sales service. It offers steel parts and components for
automobile, engineering, agricultural, and other related sector.
Mission and Vision
PSM is dedicated to produce and distribute scientific and research literature
for the progress of science and the benefit of society. Science and technology
is the vital source of national competitiveness leading to economic
development. We are committed to offer researches and research institutions
all over the world excellent services delivered in a friendly digital
environment by distinguished editors, sub-editor, reviewers and editorial
assistants based on world-class technology. Our vision is advancing science
and technology by providing a platform for collaboration of young researches
to promote science culture through publication and work to establish a
peaceful and united society. Our core drive is aimed at providing a rapid turn-
around possible time for review, publishing and to disseminate the articles
freely for teaching and reference purposes.

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REFRACTORIES
Refractory is a heat-resistant material that constitutes the linings for reactors and high
temperature furnaces. It is not only resistant to thermal stress but it can also withstand
corrosion and physical wear caused by chemical agents.
In PSM, there are four sections of refractories, described below:
    − 
Objectives of RDC:
1. To produce refractories that protect
furnace shell, ladle &tundish from molten
metal
2. To reduce wastage of temperature
Classification of Refractory on the basis of:
1. Chemical composition (Nature):
a. Acidic b. Basic c. Neutral
2. Physical (Method of manufacturing):
a. Shaped(beans, colons, bricks) b. Unshaped (Monolithic)
Refractory Manufacturing Process:
1. CALCINATION:
It has 3 zones; preheating (500 °C), heating (1400-1450 °C) & cooling zone.
After mining, material is heated in rotatory kiln at 1250 °C to remove volatile liquid.
And sulphides and carbonates are converted to oxides. Magnesia (MgO) prevents
two most important properties; erosion & thermal shock. Capacity of calcination
= 1500 – 1800 ton per year.

5
2. CRUSHING & SIEVING:
The calcined material is sent to a Jaw crusher, then to a hammer crusher and
finally to a drum. From drum, MgO (material) goes to rotating round sieve to get
the required size grains for the recipe.
First mesh no. is 40 mesh, second; 1 mesh, third, fourth, fifth & sixth are 2 mesh,
3 mesh, 4 mesh & 5 mesh. Alumina granular is called ‘Shemote’.
Crushing & calcination is done in open air & not in the shop due to pollution.
3. MIXING:
Additives, binders, clay etc. are added. After this, unshaped refractory
(monolithic) is ready.
4. PRESSING:
Brick goes to the pressing machine (Screw friction Press) for shaping, from where
‘green bricks’ are produced. Powder pressing is compulsory for shaped
refractory.
5. CINTERING:
Densification of green bricks is doneat high temperature (1350 °C) in brick
cintering furnace to achieve desired strength.
• The annual capacity of RDC is about 3000 – 4000 ton. While the
requirement is 5000 – 6000 ton.
• Refractories are made according to the geometry of furnace & its
environment.
  
• Ladle lining is performed in M-Shop&
this department deals with the
refractory lining of the ladle furnace.
• Basic refractories are magnesia,
dolomite & alumina. In PSM, they
use magnesia carbon.
• There are two main linings for ladle:
i. Working lining
ii. Permanent lining
i. Working Lining has two zones; Slag zone and Metal zone. The slag zone is
located at the top & is about 1800 mm long while the metal
zone is situated at the bottom & it’s about 186 mm long.

6
Centered magnesite brick is used in working line.
Magnesia carbon brick is used as it is thermal resistant. It is
composed of 90% Magnesia& 10-18% Carbon is in residual
carbon form. In ladle, working layer is thick because material
stays for a long period.
Working line is about 1500 mm in height & 125 mm thick in
metal zone while 150 mm thick in slag zone.
ii. The second layer consists of 7 mm micro base, 32 mm Silica
base (35% Si) & 32 mm safety lining (70% high
Alumina)Safety line is about 76 mm is at the ladle furnace’s
top & protected by ‘gunning mask’.
• Fireclay is used for sealing ladle from outer side.
• Damaged lining’s whole section is taken out & reused.
  
Tundish is a broad open reservoir for frequent or continuous supply of feed from
ladle & storing located at the down-side of the ladle.It is performed in M – Shop
& deals with the refractory lining of tundish.
A casting tundish is lined with refractory
bricks specific to the liquid metal which is
being cast.
Tundish refractory consists of:
1. Insulation sheet
2. Silica bricks
3. Fireclay bricks
4. High alumina bricks
Mostly, MgO is used in tundish for refractory
lining. For the walls of tundish, MgOC is used
of thickness 300 mm.
  

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It is interlinked with all the departments and shops wherever any
refractory is being used. Furnaces in which refractories are being used, they also
at some time need repairing. This repairing or maintenance of furnace
refractories is done in ‘downstream shop’. It is basically an inspection sectionthat
inspect the refractories being used in PSM.
(M) SHOP
MELTING

In melting shop, ‘scrap’ is the main material that is used to make steel.
The scrap consists of recyclable materials, such as parts of vehicles, building
supplies, and surplus materials.
Types of Metal Scrap:
i. Ferrous
This type of scrap consists of iron and steel
ii. Non-ferrous
PSM deals with the ferrous one.
Selection of Scrap:
It depends on the following factors:
i. Size and weight

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ii. Cost
Types of Scrap dealt by PSM:
i. Shredded (chopped)
ii. Bundles
iii. Heavy metal scrap (HMS)
iv. Rail scrap
v. Shop return scrap (endcuts and chips)
   
A bucket loaded with scrap transfers it in the EAF. Scrap is charged in this
furnace by an electric arc. Capacity
of this furnace is from 1 ton to 400
tons (approx.) but in PSM, it is
about 15 tons.
EAF has following two objectives:
i. Melting
ii. Dephosphorization
Plant Specifications:
i. No. of EAF = 2
ii. A power of 11kV is received from K.E & with the help of step-
down transformer reduced to min 230 & max 550 volts per
ton.
iii. Capacity of furnace = 15 tons
iv. Diameter of furnace;
a. Without refractory = 3.8 m
b. With refractory = 2.8 m
v. Ideal tap to tap time = 120 minutes
vi. Shell diameter = 3150 mm
vii. Electrode diameter = 305 mm
viii. In Lancing;
a. Oxygen pressure = 5-8 bar
b. Lancing time = 20-25 minutes

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ix. Slag is removed from furnace, when required
composition is achieved, by tilting the furnace 15°& it
automatically gets out from the slag door.
x. Then, it is tapped in ladle by tilting the furnace 45°. During
tapping, alloys are added.
FORMULA FOR CALCULATION OF ADDITION OF ALLOY:
When an alloy is added in molten metal, its addition is calculated by
following formula:
Required % of alloy – Given % of alloy / Recovery rate * Capacity of furnace
Processing:
OXYGEN LANCING:
It has following main purposes:
• To make slag
• To reduce consumption of electricity
• To reduce consumption time
FURNACE REACTION:
Oxygen lancing performs following reactions in the furnace:
• Reduces carbon composition in steel & produce CO gas which flows in the
air.
C + O2→ CO
• Oxygen reacts with phosphorous & prepares phosphorous pentaoxide
P2O5, it is called ‘dephosporization’.
P + O2→ P2O5

• The above reaction is reversible one so, after 1620 °C, we add lime. CaO
reacts with P2O5& forms CaP2O5.
Ca + P2O5→ CaP2O5
➢ Phosphorous gets mixed with slag & removed with it.
➢ Magnesia carbon powder is used for foamy slag formation. The foamy
slag keeps the furnace refractory safe.

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➢ When oxygen increase boiling from furnace then, to
reduce it, Ferro Silicon is used.
➢ When desired temperature is achieved in the furnace then, sample is
collected & composition is checked.
➢ For proper addition of alloy composition, standard formula is used.
➢ Basicity of slag = 1.5
  
Ladle furnace is used to raise the temperature & adjust the chemical
composition of molten metal.
• Primary functions of a ladle furnace include:
i. Reheating liquid steel through electric power conducted by
graphite electrodes.
ii. Homogenization of steel temperature & chemistry through
inert gas stirring.
iii. Formation of a slag layer that protects refractory from arc
damage, concentrates & transfers heat to the liquid steel, trap
inclusions & metal oxides, & provide the means for
desulphurization.
• Secondary functions include:
i. Alloy additions to provide bulk or trim chemical control
ii. Provide a means for deep desulphurization
iii. Provide a means for dephosphorization
iv. Act as a buffer for
downstream steelmaking
equipment
Objectives:
i. Alloy addition
ii. Desulphurization
Parameters:
i. Temperature control
ii. Refining
iii. Composition of alloy control

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i. No. of LF in PSM = 2
• LF 1 works slow
• LF 2 works at a greater speed than LF 1.
ii. Process time in LF = 30 to 35 min
iii. Diameter of graphite electrode in Lf station = 8 mm
iv. 8.5 mm transformer used
v. Ring size in ladle = 200 mm
vi. Consumable rate of electrode at this work station = 1.5 – 2 kg/ton
vii. Holding temperature at LF = 1630 – 1640 °C
viii. Ladle weight = 5570 kg
ix. Ladle height = 2880 mm
Processing:
i. Using lime, slag is made.
ii. CaO reacts with sulphur& desulphurization & makes slag.
iii. In LF, purging is done through purge plug, Argon or Nitrogen gas is used
for purging.
iv. Mostly purging is done through argon gas when special steel is used.
v. Calcium fluoride makes fluidity in slag.
vi. At this station, molten metal is heated as required for VD & CC
temperature.
Alloy Addition:
Alloy addition in this station like FeCr, FeV, SiCr, Ni, Al. All these alloys & other
alloys add as per requirement in the furnace.
Deoxidizers:
There are following deoxidizers used in LF:
Si, Mn, Al, Cr, Sn
  
A vacuum Tank Degasser (VTD) is used to reduce the concentrations of dissolved
gases (H2, N2, O2) in the liquid steel, homogenize the liquid steel composition &
bath temperature, remove oxide inclusion materials from the liquid steel &
provide the means & technical conditions that are favorable for final
desulphurization.
The fundamental requirements for the ladle degassing process include:

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i. Sufficient freeboard in the ladle to contain the
vacuum –induced slag & steel boil.
ii. An inert gas percolating through the steel bath for stirring, inclusion
separation & enhancement of vacuum degassing performance.
iii. Sufficient superheat in the steel to avoid skull formation.
iv. Means to deliver additives while the ladle is inside the vacuum tank.
Objectives:
• To remove gases from
molten metal
• To make final steel
composition
i. Types of pumps used to
reduce pressure:
a. Watering pump
b. Stream ejecting pump
ii. Watering pump = 2 & Steam ejector pump = 4
iii. No. of pumps work at a time = 2
iv. Time for whole process of vacuum degassing = 20 -25 min
Parameters:
i. Purging plug work properly
ii. Holding metal at particular pressure
iii. Plant & pumps working properly
Processing:
i. Heavy slag is made by dolomite. Dolomite is used to make heavy slag.
ii. Ladle is sealed from outer side with fireclay.
iii. For joining, rubber material is used.
iv. Initially, both watering pumps are used.
v. For vacuuming, pressure must be reduced to 1 atm (= 760 torr) & when
pressure comes to 3 – 4 torr, both pumps are stopped.
vi. Argon gas is used at this station also for purging.
vii. Ca+Si wire is used for desulphurization if needed.
viii. If boiling is created then, use ‘Al’ bar to reduce boiling.

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ix. When carbon composition in metal is low than required,
then after VD, metal is sent to VOD (Vacuum Oxygen Decarburization),
then to reduce oxygen it is sent to VCD station (Vacuum Carbon
Deoxidization).
x. When oxygen is to be reduced direct after VD, the metal is sent to VCD
station to reduce oxygen.
 
An ingot is a piece of material, usually metal, that is cast into a shape suitable for
further processing. In steel making, it is
the first step among semi-finished casting
products. Ingots usually require a second
procedure for shaping, such as cold/hot
working, cutting, or milling to produce a
useful final product. Non-metallic & semi-
conductor materials prepared in bulk
form may also be referred to as ingots,
particularly when cast by mold based
methods. Ingots are first heated at the
bottom to avoid cracks, before casting.
i. In ingot casting, bottom pouring.
ii. Cast iron molds are used.
iii. Ingot casting provides feedstock to other shops within the industry.
iv. Neutral refractories of Alumina based.
v. Through ingot casting, following types of products are prepared:
a. SQ 1100
b. SQ 1250
c. SQ 700
d. FL 2000
e. FL 1600
f. FL 1200
g. FL 1000
h. FL 600
i. R 2000
j. R 600

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k. OCT 12 ton
l. OCT 15 ton
m. OCT 2 ton
• Ingot casting prepared:
i. High Alloy steel
ii. Too steel
iii. Stainless steel
• Ingot casting products:
i. For making ESR electrode
ii. Slab casting
iii. Forging cast
iv. When there’s a power failure then ingot casting is done
Types of Casting Powder:
Three types of casting powder used at different times:
i. High carbon powder (used when low & medium alloy)
ii. Low carbon powder (used when stainless steel)
iii. Medium carbon powder (used when tool steel)
• Casting powder dip in the mold, it works as a lubricant & remove contact
with air.
• Cover powder&anti piping powder are exothermic that cause burning
thus used for filling cavity.
• Feeder head is used in mold to remove cavity.
• Before filling from ladle, heat molds & increases temperature of mold
from 50 – 60 °C.
• Arrangements of mold & refractories in ingot casting.
Processing:
First heat mold 50-60 °C, then produce cloud from argon gas to prevent contact
of molten metal with air then through ladle bottom poring & these labeling for
refractory in dumbit. In ingot casting bottom pouring, casting powder hang in
mold & cover powder & anti-piping powder use to fill cavity because when a
metal solidifies, some empty space is still remaining, then these powder burn
(exothermic) & produce heat & cavity filled through slight ladle gate control the
flow of molten metal.
 

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Continuous casting is the process whereby molten metal is solidified into
a semi-finished billet, bloom, or slab subsequent rolling in the finishing mills.
Prior to the introduction of continuous
casting in the 1950s.
Continuous casting has evolved to
achieve improved yield quality, &
productivity & cost efficiency. It allows
lower-cost production of metal sections
with better quality, due to the inherently
lower costs of continuous.
Objectives:
i. Making billets & bloom from molten metal for other industries.
ii. Molten metal solidified into semi-finished billets bloom for rolling &
forging in downstream shop.
Parameters:
i. Casting temperature
ii. Casting speed
iii. Cooling system
• Three main departments of continuous casting area:
1. Tundish area
2. Casting area
3. Runout area
• Tundish area purpose:
i. Act as a buffer between ladle & mold.
ii. Flow rate control.
iii. Act as a reservoir.
iv. Multiple stream supply easily.
v. Inclusion floatation.
• Capacity of tundish = 6 ton
• In primary cooling, since walls of mold are colder outside therefore, metal
in the mold gets its first cooling completed here.

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• Secondary cooling have 3 zones with different lengths but
total length is 6m. Flow rate decreases from zone 1 to 3.
i. Zone 1 (0.3 m)
ii. Zone 2 (2.7 m)
iii. Zone 3 (3 m)
• Metallurgical length from mold to where molten metal freeze approx. 9
mm.
• Copper molds used in continuous casting.
• Mold length = 800 mm
• Diameter of mold = 7 mm
• Temperature of heat liquidize = +50°C
• Size of ;
Billet mold= 110x110 mm, 125x125 mm & 150x150 mm
Bloom size = 230x230 mm

Tundish is a broad open reservoir for frequent or continuous supply of feed from
ladle & storing located at the down-side of the ladle.
Tundish refractory consists of:
5. Insulation sheet
6. Silica bricks
7. Fireclay bricks
8. High alumina bricks
Powders:
1. Casting Powder is used in mold for following purposes:
i. Remove contact with air
ii. Inclusion
iii. Used as a lubricant
2. Covering Powder is used in tundish for following purposes:
i. Temperature drop
ii. Remove contact with environment
iii. Inclusion not come
Processing:
i. Tundish is dried to remove moisture & preheated at 1200°C for about
90 minutes before ladle comes.

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ii. Shroud is placed at the ladle’s bottom.
iii. Molten metal flows from shroud to tundish& shroud is submerged in
tundish. This process is called ‘Submerged Entry Shroud’ (SES).
iv. Flow is controlled from slight gate & stopper system.
v. Casting & covering powders are used.
vi. Molten metal flows in copper mold & is pulled by dummy bar.
vii. Water & gas shower cools the molten metal’s outer surface.
viii. Further, it goes through three cooling zones.
ix. Required size billet is cut by a shearing machine.
x. The product is stored & left for proper cooling.
  
Defects are checked by following inspection methods:
i. Online Inspection
ii. Final Inspection
Final inspection has further two divisions:
a. Surface Inspection
This inspection shows following defects:
Cracks, Bulging, Pin holes (porous), co
b. Internal Inspection
It shows following defects:
Macro etching, blow holes (smallest size that cannot be seen with naked
eye)

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Forging
Forging is defined as a metal working process that shape work piece into
desired dimensions by compressive forces applied through the use of dies
and tools forging process is operated by hammering or pressing the metal. In
nowadays, industrial forging is done either with presses or hammers powered
by compressed air, electricity, hydraulics or steam. Some examples of
products obtained by forging process are –crane hook, connecting rod of an IC
engine, spanner gear blanks, crown wheel, pinion etc.
Die design parameter: Die design depends on the knowledge
of strength and ductility of work piece material, sensitivity of material to the rate
of deformation and temperature, frictional characteristics, shape and complexity
of work piece, die distortion under high forging loads.
Die material requirements: Strength and toughness at
elevated temperature, Harden ability and ability to harden uniformly, Resistance
to mechanical and thermal shocks, Wear resistance to resist abrasion wear due
to scales present on work piece.
Type of forging
• Open die forging
• Close die forging
Type of forging equipment
• Hammer forging
• Press forging
Type of forging shop
• R1(Die forging)
• R2(press forging)
• P2(long forging machine)

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R1SHOP
(DIE FORGING):
INPUT:
• Round bars(dia 38mm,60mm)
• Flat
• Square
OUTPUT:
• Gear blank
• Round bars (12mmto 50mm)
• Square(12mm to 50mm)
PLANT CAPABILITY:
• Re-heating furnaces:
In steel plants reheating furnaces are used to heat the steel stock (billets, blooms
or slabs) to temperatures of around 1200 deg C which is suitable for plastic
deformation of steel.
FURNACES TYPE=batch furnaces.
Fuel=gas fire.
Furnace Capacity=100 kg, 200kg, 300kg.
• Band saw machine:
A band saw is a saw with a long, sharp blade consisting of a continuous band of
toothed metal stretched between two or more wheels to cut material.
Thickness cutting range=150mm, 200mm, 400mm.
Lubricant is used to increase blade life by reducing friction.
• Hammer forging machine:
Hammer forging machine are mechanical forging hammers hat use a non-
muscular power source to raise the hammer preparatory to striking, and
accelerate it onto the work being hammered.
• Trimming Machine:
Trimming machine is manufacturing processes in order to achieve the best
possible results for forged parts, in order to remove flash.

20
• Heat Treatment:
Heat treatment involves the use of heating or chilling, normally to extreme
temperatures, to achieve a desired result such as hardening or softening of a
material. Heat treatment techniques include annealing, case hardening,
precipitation strengthening, tempering, carburizing, normalizing and quenching.
Procedure of making round bar.
• First we take a large metal piece and cut through band saw machine
according to output weight.
• After cutting a metal piece ,goes toward furnace for re heating up to 1200
degree centigrade.
• After heating material, billet is placed in hammer forging; upper die and
ram are raised by friction rolls griping the board.
• Die of desire output diameter is use.
• The hammer can strike between 60-150 blows per minute depending on
size and capacity. Energy will be delivered to the metal work piece to
produce plastic deformation.
• Diameter is check through vernier caliper.
• Hammered the metal piece we kept in the air for cooling.

21
Defect:
• Cold shut:
This appears as a small cracks at the corners of the forging .
• Flakes:
These are basically internal rupture caused by the improper cooling of the large
forging .
• Scale pits:
This is seen as irregular deputations on the surface of the forging .
Removal of defect:
• Trimming (trim the irregular end ).
• Grinding(removed scale on the surface of metal piece).
R3 SHOP
(PRESS FORGING):
INPUT:
Ingot casting(sq 700,sq1250,oct 2000,oct 3000 oct 5000,oct 8000,oct 12000).
ESR material ( dia 400mm, 600mm, 750mm).
OUTPUT:
Round bars (dia min 200mm, max 500mm).
Sq block/ bars (max 450mm).
Forging shapes:
Disk (max dia 200mm).
Rectangular block.
Ring (min dia 1500mm and max dia 200mm) (length 300mm).

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PLANT CAPACITY:
• Re-heating furnace:
Re-heating are used to heat the metal piece (billed,ingot,bloom)to temperatures
of around 1200 deg C which is suitable for plastic deformation of steel.
Furnace capacity 40Mton, 20Mton
Temperature range=1400.
Fuel=air and gas mixture.
Manipulator:
Manipulator is a device used to manipulate material without direct contact.
Manipulator capacity 15 ton.
Mobile Manipulator of capacity 3 ton.
Press forging machine:
Press forging is a method of forging that involves the slow and continuous
application of pressure on the work piece .compression is used in a number of
different ways to shape the metal and can be carried out in cold, warm and hot
conditions.
Forging press force of 1700 ton.
It’s work on hydraulic mechanism.
Heat treatment:
Heat treatment involves the use of heating or chilling, normally to extreme
temperatures, to achieve a desired result such as hardening or softening of a
material. Heat treatment techniques include annealing, case hardening,
precipitation strengthening, tempering, Carburizing, normalizing and quenching.
Procedure:
• First Ingots is re-heated in the furnace upto 1200deg C.
• Ingot is takeout in furnace through rail bound manipulator.
• Ingot is press forged upto desire output diameter is obtained.
• After found required ingot, is placed into annealing furnace for heat
treatment

23
.
Defects:
• Surface cracking.
• Pit marks.
• Internal ruptures
Removal of defect:
• Remove surface cracking to increase the work temperature.
• Pit marks is remove by proper cleaning

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P-1 SHOP
(HOT ROLLING MILL):
INPUT:
SHEETS DIAMETER (8MM- 22MM)
OUTPUT:
SHEETS DIAMETER (3MM-8MM)
THICKNESS (950-1000MM)
PROCESS:
➢ CHARGING
➢ FURNACE (WALKING BEAM)20M LENGTH
➢ ROUGHING MILL
➢ SHEARING

25
P-2 shop
(Long forging machine):
input:
1. Bloom ( 230mm)
2. Billet ( 110,125,150mm)
3. Octa 230
output:
1. Round bar dia50mm
2. Square 50mm
Process:
1) Re-heating furnace:
In steel plants reheating furnaces are used in hot rolling mills to heat the steel stock
(Billets, blooms or slabs) to temperatures of around 1250 deg C which is suitable for
plastic deformation of steel and hence for rolling in the mill.

26
Capacity:
• Material is reheated in reheating furnace.
• Walking beam furnace.
• 3 zone
• 14 burner
• 6tonn/hr.
2) Radial Forging.
• 2 chuck head A/B.
• 4 hammers.
• Material fixed in chuck head A.
• Hammer angle changed according to material type.
• Material passes through passes max. 30mm.
• 415 strikes per minute.
3) Hot abrasive cutting machine:
• if cutting required
• cutting wheel diameter 1m , thickness 10mm, RPM 1900
4) Two Heat treatment furnaces:
Austrian:
• 15 metric ton capacity.
• Gas fired
• PLC control.
• 14 burners.
• 3 zone.
• +/- 2 degree Celsius variation.

27
Chinese:
• 10 metric ton capacity.
• 6 burners.
• 3 zone.
• +/- 15 degree Celsius variation.
• Gas fired.
5) Finishing product:
• Peeling
• Grinding
(Q-SHOP)
BAR ROLLING MILL
Objective:-
1. Reduction of diameter.
2. Increase length
Input:-
Input of bar rolling shop “billet (110,125,150)”
Output:-
There are three types of product of Q shop, which are listed below:-
1. Round bar (dia 18mm to 80mm and
length 4-6m)
2. Flat bar (length= 3-6m)
(thickness=6mm-12mm)
(width=50mm-120mm)
3. Deform bar (19mm, 25mm, 32mm,
36mm)

28
Plant specification:-
• Re-heating furnace:-
In steel plants reheating furnaces are used in hot rolling mills to heat the steel
stock (Billets, blooms or slabs) to temperatures of around 1250 deg C which is
suitable for plastic deformation of steel and hence for rolling in the mill.
▪ Capacity: 6tonn/hr
▪ Temperature range= 1260 deg C-1500 deg C
▪ Zone=2 (socking zone, top zone)
▪ Burner= 4 (2 socking, 2 top)
▪ Refractory= Cast able bricks
▪ Fuel= gas air mixture
• One Rough mill (3 Cast steel rolls for rough mill)
A rough mill is a rolling mill for converting steel ingots into blooms, billets, or
slabs. The roughing mill consist of passes of different sizes.
• Five Finish rolls (F1 to F4 3 rolls, at F5 2 rolls.)
• Hot shearing machine: To cut the rolls into equal parts
• Cold sharing machine: to remove the defected parts and End cuts
• Heat treatment furnace:
Heat treatment involves the use of heating or chilling, normally to
extreme temperatures, to achieve a desired result such as hardening or softening of
a material. Heat treatment techniques include annealing, precipitation
strengthening, tempering, carburizing, normalizing and quenching.
▪ Capacity of the furnace= 13ton
▪ Temperature range= 900 deg C-1200 deg C
▪ Zone=2
▪ Burner= 10
▪ Refractory= mortar Cast able bricks
▪ Fuel= gas air mixture
PROCESS FOR MAKING FLAT BAR
1. First billet heat in re heating furnace.
2. Then after heating and soaking material pass seven times through rough
mill roller, in rough mill 50% reduction thus we use cast steel rolls, in
rough mill.

29
3. top and bottom roller move clockwise direction and middle roller move in
anticlockwise direction, continuous water showering to cooling roller
inside and outside.
4. Then divided piece in 2 equal length through hot shearing machine.
5. Then material pass through finish mill roller and then at F5 our required
dimension material is obtained through F5 roll pass, in finish mill roller
cooled through outside water showering.
6. then material forward to cooling bed.
7. Then cut the
defected parts
through cold
shearing machine.
DEFECTS:
Every material have different defect in which some defect shown below:
Crack, rolled out, Fin, Size variation, Seam, Folding
Mpi test:-
Magnetic particle Inspection (MPI) is a non-destructive testing (NDT) process for
detecting surface and shallow subsurface discontinuities in ferromagnetic materials
such as iron, nickel, cobalt, and some of their
alloys.
In this test, the material is magnetized and
then uv light is applied over the material , in
this way any crack would be visible.

30
(N-SHOP)
BLOMMING AND SLABBING MILL
Every shop have some inputs and outputs.
INPUTS:
1. Flat ingot.
2. Square-ingot.
3. Cast slab (Import) (M.s material).
4. Bloom (SQ-230*230mm).
5. Billet (SQ-150mm).
OUTPUTS:
1. Plate (10mm to 80mm thickness).
2. Blooms (SQ-230*230mm) these blooms also called rolled bloom &
billets (SQ-100mm)
3. Round bar ( 110mm, 140mm)
4. Gothic bar (SQ-76mm).
PLANT CAPABILITIES:
• Re-heating furnaces
Re heating furnace is use to soft the material by providing the temperature
above recrystalize tempersture.
➢ Furnace temperature 1250degree centigrade.
➢ capacity of furnace.9ton/hr.
• 2-HI Reversible mill
• Plate leveler.
• Diameter of roller=820mm.
• Roll length=1800mm.
• Max plate width pass through
roller 1500mm.

31
PROCESS OF PLATE PREPARATION:
1. First cast slab heated in re-hearing furnace.
2. Then slab pass through two rollers. Top roller gradually move downward
while bottom roller is fixed. The rollers move in opposite direction in to
and fro movement.
3. Then hot shearing machine cuts plates end cuts.
4. Then plate pass through leveler to straight the plate.
DEFECTS:
Every material have different defect which are listed below:
▪ PLATE: Pitting, Cracks, Edge cracks, Waviness.
▪ ROUND BAR: Seam, Folding, Cracks, Fin
▪ BLOOM: Folding, Cracks.
▪ GAUTHIC BAR: Cracks, Seam(internal cracks)

32
Removal of defects:-
▪ Grinding
▪ MPI Test (magnetic particle inspection test)
▪ Water jet spray is applied on slap/ plate to remove the scale.
WATER TREATMENT PLANT:
INTRODUCTION:
People steel mill is dependent on water for many area of plant operation. Water is used
to quench or cool steel surface and furnaces throughout many stages i.e. Casting,
cutting, rolling, forging.
WATER TREATMENT CONSIST OF:
• Control of corrosion
• Control of scaling
• Control of microbiological fouling
• Control of general dirt and debris
FLOW
DIAGRAM:
X-shop
industrial
water
oxidation
pound
oil skimming
pound
Agitator
cooling
tower
storage
pound
Q, N,R-
shop/WTP
fresh
water
cooling
tower
Q, N, R-
shop/ WTP
drinking
water
domestic
filters

33
PLANT CAPACITY:
1. X-SHOP:
• Main shop for water treatment, storage and distribution. It stores
• Fresh water tank
• Industrial water tank
• Drinking water tank
2. SOFTNER TANK:
• Contain zeolite bed of sodium resin to remove ca+2 and mg+2 ions
• Capacity: 60m3 /h
• After 525m3
flow zeolite bed need to be recharged by back flow of brine.
3. PUMP SPECIFCATIONS:
CC/ Shear cutter/molds:
• Type: Centrifugal pump.
• Capacity: 200m3
/hour
• Pressure: 5-6bar
• No. of pumps: 3
Furnace/ EAF/LF:
• Capacity: 285m3
/hour
• Pressure: 5bar
• No. of pumps: 3
VD(vacuum degassing):
• Capacity: 65m3
/hour
• Pressure: 4.5bar
• No. of pumps: 2
4. HEAT EXCHANGER:
• Consist of 84 plates
• There is no mixing of hot and cold water because of gas jets.

34
5. COOLING TOWER:
• Type: cross flow.
• Cells: 1/2 cells.
WATER TREATMENT PROCESS:
INDUSTRIAL WATER TREATMENT:
• Water after performing cooling on
secondary basis is sent to x-shop.
• First water is stored in reservoir, whose
bottom is fitted with air blower, oxygen
is supplied through it and traces of iron
are oxidized forming precipitates.
• Then oxidized water is stored in oil
skimming reservoir. Due to density
difference oil floats on water and is
skimmed in small tank.
• After removal of oil water is send to
agitator where aluminum silicate
(AL2(SO4)3and soda ash are added.
• Aluminum silicate settle down sand and other impurities while soda ash
maintains ph.
• Then water is sent to cooling tower.
• After reaching the desire temperature water is stored and ready to use.
• Q, N, P and R-shop water is directly sent while for M-shop water is first send to
water treatment plant (WPT).

35
WATER TREATMENT PLANT ( For M-shop):
Water from x-shop is transported to
WTP for M-shop and passed through
filter (gravel bed) tank removing
precipitates.
• Dust free water than pass
through softener, it consists of
zeolite bed (sodium resin) to
remove hardness caused by
ca+2 and mg+2 ions.
• Corrosion inhibitor(N24209) is
added to reduce corrosion rate.
• Satisfying all the parameters of
treated water. water is
transportedthrough pump to m-shop for cooling purpose.
• By Cooling the operation, temperature of cold water raises. For efficient cooling,
water passes through heat exchanger to exchange heat.
• On one side of heat exchanger cold water flows while on the other side hot water
flows.
• Cold water in heat exchanger absorbs energy from hot water and send water
again for cooling purpose.
• Then same process is repeated.
TREATED WATER PARAMETERS:
1. Iron level:
• Iron level should be below 3ppm.
• Tested by titration method.
2. Ph.
• Range 8.5-10.5(basic).
3. Nitrate test:
• Range 600-800ppm.
• Strip test

36
4. Conductivity:
• Low conductivity
5. TDS:
• Range 1000-1500
6. Hardness:
• 20ppm
QAD LABORTARY:
People steel mill have large focus on their testing technology and they have advanced
technology for testing and inspection of more than 300 steel grades.
There are number of labs in quality assurance department
1. Optical emission spectroscopy lab.
2. Rapid Analyzer.
3. XRF spectrometer lab.
4. Metallography.
5. Wet chemical analysis.
6. Mechanical testing.
7. Magnetic particle testing.
8. Ultrasonic testing
9. Liquid penetrant testing.
1. OPTICAL EMISSION SPECTROSCOPY LABORTORY:
2. Online material composition testing is done
in spectra lab.
3. Sample from m-shop is sent to workshop.
In workshop sample is cut then polished by
emery paper of 40,60.
4. Polished sample is send to spectra lab and
composition of sample is checked by OES.
5. Sample is placed on sample table, a
distance above tungsten electrode which
provide ignition at 1000 volt.

37
6. Argon gas is purged (5m/min ) to provide inert atmosphere
7. Outer electron of sample absorb energy from ignition and move to higher
orbit.
8. After emitting unique radiation electron return to its original position.
9. These radiations travelled through diffraction grating and radiation breaks
into its component.
10. The intensity of each emission spectrum depends on the
concentration of the element in the sample.
11. Detectors (photomultiplier tubes) measure the presence or absence of the
spectrum extracted for each element to perform qualitative and quantitative
analysis of the elements.
2. RAPID ANALYZER:
When amount of Sulphur and carbon is critical and show error.
Then sample is send to rapid analyzer lab for accurate
composition. Rapid analyzer lab consist of 2 carbon- Sulphur and
2 hydrogen-nitrogen-oxygen determinator.
CARBON/SULPHUR DETERMINATOR.
1. Analyze: Carbon (1-6%) and Sulphur (0.35) composition.
2. Carrier gas: Oxygen (from furnace to detector)
3. Crucible: Ceramic made and tungsten powder fill in it.
4. Sample: chips from (latte machine/ machine shop).
5. Furnace: induction coil furnace.
6. Detector: infrared cell (IRC) 2 for carbon and 1 for Sulphur
HYDROGEN/NITROGRN/OXYGEN DETECTOR.
1. Analyze: hydrogen / oxygen/ nitrogen percentage.
2. Carrier gas: argon for O and H and helium for O andN (from furnace to detector)
3. Crucible: Graphite made.
4. Sample: pins and balls.
5. Furnace: impulse furnace.
6. Detector: infrared cell for O, thermo couple cell for N
and H.
7. Schmutz reagent: convert CO to CO2.
8. Detection range: O and N is 20,000ppm, H is
1000ppm.

38
3. XPR SPECTROMETER:
1. Composition of sample is determine by bombarding x-ray on the sample.
2. x-ray beam with enough energy to affect
the electrons in the inner shells of the
atoms in a sample is created by an x-ray
tube.
3. The x-ray beam then interacts with the
atoms in the sample by displacing
electrons from the inner orbital shells of
the atom.
4. When electrons are knocked out of their
orbit, they leave behind vacancies, making
the atom unstable.
5. Those vacancies can be filled from higher
orbits that move down to a lower orbit
where a vacancy exits.
6. An electron loses some energy when it drops from a higher electron shell
to an electron shell closer to the nucleus.
7. The amount of energy lost is equivalent to the difference in energy
between the two electron shells, which is determined by the distance
between them. The distance between the two orbital shells is unique to
each element,
8. The energy lost can be used to identify the element from which it
emanates, because the amount of energy lost in the fluorescence process
is unique to each element.
9. It can be used for a wide range of elements, from beryllium to uranium (64
elements)
4. MATELLOGRAPHY:
• Metallography is the study of the physical structure and components
of metals, by using microscopy.
• Microscopic examination of polished or etched surfaces at
magnifications ranging from about 100 to 1,500 diameters can reveal
such information as size and shape of grains, distribution of structural
phases and nonmetallic inclusions, micro segregation, and other
structural conditions.

39
Steps of metallography:
1. CUTTING:
Cutting a small piece of metal to study. Cutting technique can change
the microstructure of sample.
2. MOUNTTING:
Small sample are mounted in plastic for convenience handling and to
protect the edges.
3. GRINDING:
The entire process is done to obtain a scratch free surface.
4. POLISHING:
To remove deformation from grinding and obtain a surface that is highly
reflective.
5. ETCHING:
Etching occurs when acid or base is placed on specimen surface. It
high lights microstructure of sample.
5. WET CHEMICAL ANALYSIS:
1. It can analyze refractory material , ferrous and non-ferrous material.
2. Wet Chemistry, also called wet chemical analysis, generally refers to
chemistry performed on samples in the liquid phase. Since wet
chemistry analysis is performed on liquid samples, this type of element
analysis can often be performed on samples too small for other
instrumental methods.
6.MECHANICAL TESTING
There are five basic test:
1. Hardness
2. Ultimate tensile test
3. Toughness
4. Ductility
5. compression

40
HARDNESS TEST
Brinell hardness test:
Brinell hardness test is used to determine the hardness of any material.
1. In this test load is applied gradually.
2. This test can be used for both ferrous and non ferrous material.
3. For ferrous materials load is applied for about 15 seconds and pho nonferrous
materials load is applied for 30 seconds.
4. In this test we use a steel ball indenter of diameter 10 MM with a bilateral
tolerance of 0.01 MM but for testing harder materials we can use a tungsten
carbide ball.
PROCEDURE:
1. First of all specimen is placed on anvil and anvil is raised by rotating hand
wheel.
2. Specimen is brought in contact with steel ball after that the load is applied
3000kg by rotating crank lever at right side of the machine.
3. To calculate the brinell hardness number the diameter of all indent produced in
specimen is measured.
ROCKWELLS HARDNESS TEST:
The rockwells hardness test is generally performed
when quick and direct reading is desirable.
This test is also performed when the materials have
hardness beyond the range of brinells hardness
test.
Start minor force then HRB 100kg, HRC 150kg
force.
HRB=ball intender use, HRC diamond cone intender
use.
Size limitation in brinell we use Rockwell because in
brinell thin sample not test.

41
ULTIMATE TENSILE TEST:
Ultimate tensile test is measured by the maximum stress that a material can withstand
while being stretched or pulled before breaking .In the study of strength of materials,
tensile strength, compressive strength, and shear strength can be analyzed
independently.
UTS machine used to measure:
• Tensile strength
• Yield strength
• Breaking and fracture point
• Ductility
• Compressive
• % elongation
BASIC PRINCIPLE
• Strain stress curve
• Load displacement curve
TWO TYPES OF TENSILE MACHINE:
Instron:
• 60ton force
• Engliand based
• Wedge type gripping system
• Hydraulic
PAEKYUNG TECH:
• 100ton force
• Korean based
Two types of specimen:
• Round
• Flat

42
TOUGHNESS
Toughness is a property, which is capacity of a material to resist fracture,(crack
propagation), when subject to impact. The machine measures the amount of energy
absorbed by the specimen for the rapture in
TOUGHNESS TEST:
Charpy impact test
• The specimen is supported as a simple beam with the load applied at the center.
• The position of latching tube is set to 140 degree
• The specimen is supported horizontally from two sides
PROCEDURE
• The load is applied as an impact from a hammer
that is released from position h1.
• The pendulum with a knife edge strikes and
fractures the specimen at the notch.
• The pendulum continues its swing rising to
maximum height h2, which is lowers than h1.
• The energy is calculated from the difference in
initial and final heights of the swinging pendulum.
Impact energy (toughness) from the test is
related to the area under the total stress-strain
curve.
7. Magnetic Particle Testing (MT)
Magnetic particle testing is a relatively simple test method that can be applied to
ferromagnetic materials including finished articles, billets, hot rolled bars,
castings and forgings. Magnetic particle testing requires magnetising the piece to
be examined, applying the inspection medium or particles, and interpreting the
patterns formed by the particles when they are attracted to the magnetic

43
leakage field created by discontinuities in the part. Magnetic particle
testing is performed using visible or fluorescent mediums; the particles can be
wet (suspended in a fluid) or in the form of a dry powder.
8.Ultrasonic Testing (UT)
Ultrasonic testing (UT) is a family of non-destructive testing techniques based on the
propagation of ultrasonic waves in the object or material tested. In most common UT
applications, very short ultrasonic pulse-waves with center frequencies ranging from
0.1-15 MHz, and occasionally up to 50 MHz, are transmitted into materials to detect
internal flaws or to characterize materials. A common example is ultrasonic thickness
measurement, which tests the thickness of the test object, for example, to monitor
pipework corrosion.
Ultrasonic testing is often performed on steel and other metals and alloys, though it
can also be used on concrete, wood and composites, albeit with less resolution. It is
used in many industries including steel and aluminum construction, metallurgy,
manufacturing, aerospace, automotive and other transportation sectors.

44
9.LIQUID PENETRANT TESTING (LPT) :
Dye penetrant inspection (DPI), also called liquid penetrant inspection (LPI)
or penetrant testing (PT), is a widely applied and low-cost inspection
method used to locate surface-breaking defects in all non-porous materials
(metals, plastics, or ceramics). The penetrant may be applied to all non-
ferrous materials and ferrous materials, although for ferrous components
magnetic-particle inspection is often used instead for its subsurface
detection capability. LPI is used to detect casting, forging and welding
surface defects such as hairline cracks, surface porosity, leaks in new
products, and fatigue cracks on in-service components.

45
Reviews:
We are very thankful to all the staff in psm. We have learnt a lot from
this internship. We are also grateful for having a chance to meet so many
wonderful people and professionals.
One thing that we observed was the safety factors. During M-Shop
was continuously observing leniency against safety. The workers had no
helmet, no uniform even not had the proper gear for their safety. Not only
in M-Shop but in every shop there was such leniency. We were also not
been asked or to were provided with any protective gear.
In last we are very grateful to all of you to give such a precious time
and the fruitful information.
Thanks a lot from all of us!

Report of Pakistan Steel Mill

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Report of Pakistan Steel Mill