A PROJECT REPORT ON
“Eliminating corner gap in sc mould at LD2 SNC”.
During the internship the following research is evaluated and being verified by the authorized TATA steel employee.
The document discusses the process of steelmaking at Tata Steel's plant in Jamshedpur, India. It describes the key units involved, including hot metal receiving and desulfurization, basic oxygen steelmaking in converter vessels, secondary metallurgy treatments in ladle furnaces, and continuous casting of final products. It focuses on the secondary metallurgy processes used to refine molten steel and achieve the desired compositions for different grades, such as additions of alloys and slag.
The document provides a vocational training report submitted by Gunjesh Kumar detailing his training at Bokaro Steel Limited from June 16th to July 12th 2014. It includes:
- An introduction to Steel Authority of India Ltd (SAIL) and Bokaro Steel Plant.
- Summaries of Gunjesh's training and exposure to various processes at Bokaro Steel Plant including the sinter plant, blast furnace, steel melting shops, continuous casting, slab mill, and hot strip mill.
- Acknowledgements from Gunjesh thanking those who supported and guided him during his training.
EFFECT OF CASTING PARAMETERS ON MACROSTRUCTURE OF STEELSurya Teja Botu
The document summarizes a student project conducted at Vizag Steel Plant investigating the effect of casting parameters on the macrostructure of steel. It was presented by five students and guided by P.V. Bhujanga Rao of Vizag Steel Plant. The project examined how melt temperature and casting speed influence steel structure and defect formation during continuous casting, and modeled temperature and melt flow in the caster sump. It provides background on Vizag Steel Plant and describes its raw material sources, production units including coke ovens, sinter plant, blast furnaces, and rolling mills.
SINOM GROUP CO., LTD. is one of the largest manufacturer of copper mould tube in China. Based on customers requirement, we design, manufacture and install the square copper mould tube, round copper mould tube, beam blank, rectangular copper mould tube, diamond type, non-standard type etc.
The document discusses the vocational training presentation at Durgapur Steel Plant. It provides background on the plant, including its establishment, expansion, products, operational departments, and flow chart. It then focuses on the Merchant Mill, describing its production of plain and Thermo-Mechanically Treated bars using a continuous Morgan design mill. The process involves reheating slabs to 1100-1200°C then rolling and quenching to form the TMT bars, which are inspected for mechanical properties. The presentation concluded with familiarizing the trainee with the steel plant environment and processes.
The document provides information about the steel melting shop (SMS) at Jindal Steel and Power Limited (JSPL) Raigarh plant. The key points are:
1. The SMS has a capacity of 3.2 million tonnes per year and includes 3 electric arc furnaces, a ladle refining furnace, and vacuum degassing units.
2. The melting process involves charging raw materials into the electric arc furnaces and applying electrical energy to melt them. Secondary refining then occurs in the ladle refining furnace and vacuum degassing units.
3. Final products are continuously cast into blooms, billets, rounds and other sections using various casters like the
The document discusses the process of steelmaking at Tata Steel's plant in Jamshedpur, India. It describes the key units involved, including hot metal receiving and desulfurization, basic oxygen steelmaking in converter vessels, secondary metallurgy treatments in ladle furnaces, and continuous casting of final products. It focuses on the secondary metallurgy processes used to refine molten steel and achieve the desired compositions for different grades, such as additions of alloys and slag.
The document provides a vocational training report submitted by Gunjesh Kumar detailing his training at Bokaro Steel Limited from June 16th to July 12th 2014. It includes:
- An introduction to Steel Authority of India Ltd (SAIL) and Bokaro Steel Plant.
- Summaries of Gunjesh's training and exposure to various processes at Bokaro Steel Plant including the sinter plant, blast furnace, steel melting shops, continuous casting, slab mill, and hot strip mill.
- Acknowledgements from Gunjesh thanking those who supported and guided him during his training.
EFFECT OF CASTING PARAMETERS ON MACROSTRUCTURE OF STEELSurya Teja Botu
The document summarizes a student project conducted at Vizag Steel Plant investigating the effect of casting parameters on the macrostructure of steel. It was presented by five students and guided by P.V. Bhujanga Rao of Vizag Steel Plant. The project examined how melt temperature and casting speed influence steel structure and defect formation during continuous casting, and modeled temperature and melt flow in the caster sump. It provides background on Vizag Steel Plant and describes its raw material sources, production units including coke ovens, sinter plant, blast furnaces, and rolling mills.
SINOM GROUP CO., LTD. is one of the largest manufacturer of copper mould tube in China. Based on customers requirement, we design, manufacture and install the square copper mould tube, round copper mould tube, beam blank, rectangular copper mould tube, diamond type, non-standard type etc.
The document discusses the vocational training presentation at Durgapur Steel Plant. It provides background on the plant, including its establishment, expansion, products, operational departments, and flow chart. It then focuses on the Merchant Mill, describing its production of plain and Thermo-Mechanically Treated bars using a continuous Morgan design mill. The process involves reheating slabs to 1100-1200°C then rolling and quenching to form the TMT bars, which are inspected for mechanical properties. The presentation concluded with familiarizing the trainee with the steel plant environment and processes.
The document provides information about the steel melting shop (SMS) at Jindal Steel and Power Limited (JSPL) Raigarh plant. The key points are:
1. The SMS has a capacity of 3.2 million tonnes per year and includes 3 electric arc furnaces, a ladle refining furnace, and vacuum degassing units.
2. The melting process involves charging raw materials into the electric arc furnaces and applying electrical energy to melt them. Secondary refining then occurs in the ladle refining furnace and vacuum degassing units.
3. Final products are continuously cast into blooms, billets, rounds and other sections using various casters like the
The document summarizes Arpan Paul's 7-week summer training at JSW Steel's Kalmeshwar plant in India. It includes a certificate certifying his completion of the training. The plant details section describes the plant's production lines including continuous pickling, cold rolling mills, galvanizing, galvalume coating, and color coating lines. It outlines the plant's layout, production portfolio, quality certifications, and department details.
The document summarizes Jindal Steel and Power's integrated steel plant in Angul, Odisha. The key points are:
1) Jindal Steel has invested $6 billion to set up a 12.5 MTPA steel plant and 2,600 MW power plant in Odisha.
2) The first phase is a 6 MTPA steel plant in Angul. A 2.5 MTPA steel melting shop and 1.5 MTPA plate mill have been commissioned.
3) The plant uses DRI-BF-EAF technology and has facilities like a coal washery, sinter plant, and blast furnace to produce steel. The plate mill can produce the widest
This presentation covers all the processes and sub-processes undergoing in the newly installed department in Tata Steel ,i.e., LD3 & TSCR.
This presentation deals with the all the problems faced by this department midway through the process, and mainly focussing on "Bleeding Breakout" problem in TSCR shop.
Also an attempt is made to improve the so-called problem by suggesting certain measures at the end.
Bhilai Steel Plant is a unit of Steel Authority of India Limited (SAIL), which is one of the largest state-owned steel producers in India. The presentation provides an overview of BSP, including its establishment, products, production processes, key departments, and achievements. BSP has an annual production capacity of over 3 million tons and specializes in producing rails, plates, and structural steel. It describes the key production facilities and processes, including the rail and structural mill, plate mill, and steel melting shops. The presentation also outlines some of BSP's certifications and awards it has received for its products, safety, sustainability, and corporate social responsibility efforts.
The document provides an overview of the steel melting shop (SMS) at Jindal Steel and Power Limited (JSPL). It describes the key equipment in the SMS including electric arc furnaces, ladle refining furnaces, vacuum degassing units, and continuous casters. It also summarizes the main processes like primary refining at the electric arc furnace and secondary refining at the ladle refining furnace. Safety rules and precautions for working in the SMS are highlighted at the end.
Study Of Bleeding Breakout In Thin Slab CasterShubham Thakur
This documentation deals with the all the processes and sub-processes undergoing in the newly installed department in Tata Steel ,i.e., LD3 & TSCR, mainly focussing on "Bleeding Breakout" problem in TSCR shop.
The document summarizes key aspects of secondary steelmaking processes. It discusses homogenization through ladle stirring using argon bubbling or electromagnetic stirring. Degassing processes like ladle degassing and circulation degassing are also covered, which are used to remove gases from steel. Other secondary steelmaking stages discussed include heating in the ladle furnace, deoxidation using aluminum, decarburization in vacuum degassing, and desulphurization in the ladle through slag-metal reactions. Injection metallurgy techniques like powder injection and wire feeding are also summarized for adding alloying elements to molten steel.
The document summarizes the steel making process. There are two major commercial processes - basic oxygen steelmaking and electric arc furnace. Basic oxygen steelmaking involves blowing oxygen through molten pig iron to reduce the carbon content and produce steel. Electric arc furnace uses high currents to melt steel scrap and convert it into liquid steel. The document also categorizes different types of steel like carbon steel, alloy steel, stainless steel, and tool steel based on their chemical compositions and applications.
TMT steel is a type of reinforced steel used in concrete structures that undergoes a thermo-mechanical treatment process. This process integrates work hardening and heat treatment into a single step, resulting in bars with excellent corrosion resistance that do not require cold twisting. TMT steel is commonly used in bridges, buildings, dams, and other concrete structures. It has a carbon content of 0.3%, sulfur content of 0.05%, and manganese content of 0.5-1.2%, along with other properties that make it well-suited for concrete reinforcement.
I had done my 2 weeks Vocational Training from Bhilai Steel Plant, Bhilai situated in Chhattisgarh. I am sharing my final internship report which I made for the submission in my University.
This is a practical training of seminar report. In this seminar report all the procedure is include which is use in the industry to how to make a steel and CBRS Department is also include where the engine parts is repair.
This document discusses the process of steel making. It begins by introducing steel and its types, which are classified based on carbon percentage as carbon steel, stainless steel, and alloy steel. It then describes the main steel making methods. The basic oxygen furnace uses carbon-rich pig iron and oxygen to produce low-carbon steel. The electric arc furnace produces specialty steels by heating scrap metal with an electric arc. Secondary steelmaking processes such as argon oxygen decarburization further refine the steel through decarburization, desulphurization, and alloying.
Dear Readers,
In this presentation, I have tried to explain main raw material sources of iron making process. Also, with my experience, I have tried to give a concept about the plant engineering related to raw material. I hope that, this presentation will be helpful for young engineers. With this presentation they will get a broad idea about the raw material, based on which they can study more on the subject.
Regards,
Nirjhar.
Ladle Metallurgy: Basics, Objectives and ProcessesElakkiya Mani
Worldwide steel production in 2019 reached 1869 million tons, with China as the largest producer at 996 million tons. India was the second largest steel producer at 111 million tons. Ladle metallurgy involves further refining of molten steel in a ladle after tapping from a converter or electric furnace. It allows for homogenization, deoxidation, desulfurization, and other processes. Key ladle metallurgy techniques include ladle furnace treatment, argon stirring, vacuum degassing, and alloy additions to adjust steel chemistry and properties.
The document discusses the structure and properties of metallurgical slags. It states that slags comprise complex compounds of oxides from gangue minerals and sulphides that protect the metal melt. The structure and properties of slags, such as basicity and viscosity, are controlled by their composition. Network forming oxides like SiO2 form stable hexagonal networks, while network breaking oxides like CaO disrupt these networks. The fraction of ionic and covalent bonding in oxides determines their behavior in slags.
This document summarizes the process of preparing a tundish for continuous casting of steel. It discusses what a tundish is, the different lining layers including insulation, backup, and working linings. It details the steps to deskull, cool, and apply each lining layer. Key tundish furniture like the submerged entry nozzle and stopper are also described. The final steps of preheating the tundish and attached equipment before use in continuous casting are outlined.
I have done my industrial summer training from Bhilai steel plant which is a unit of SAIL. this is powerpoint presentation of my summer training. it includes all basic knowledge about the plant, process of manufacturing of steel and the factories inside it. you can get to learn new things from this presentation. Thank You !!
This training report summarizes Santosh Kumar's summer training at the Rourkela Steel Plant from May to July 2014. It thanks the employees who supported and guided his training, particularly Mr. Panda and Mr. Patra. The report focused on gaining knowledge about the various processes used at the steel plant, especially in Steel Melting Shop-II.
The blast furnace is an important industrial process used to extract iron from its ore. Raw materials like iron ore, limestone, and coke are input into the blast furnace where a blast of hot air helps coke burn and generates high temperatures to remove oxygen from the iron ore, leaving behind iron. The extracted iron contains impurities that are later removed in the basic oxygen furnace to produce steel.
Continuous casting is a steelmaking process where liquid steel is solidified into a semi-finished billet, bloom, or slab. In this process, liquid steel flows from a ladle into a water-cooled copper mold. As the steel exits the mold, it begins to solidify on the surface while the core remains liquid. The semi-solid steel strand is then cooled further through water sprays to fully solidify it into the desired cross-section. The continuous casting process allows for higher productivity and quality than traditional ingot casting.
Since the 1976 outbreak of Legionnaries’ Disease in Philadelphia, data continues to demonstrate how dangerous Legionella Pneumophila bacteria are to the general public. In 2010, the Center for Disease Control (CDC) reported 3,346 deaths and up to 18,000 hospitalizations were related to Legionella. The CDC also states that there are many infections that are not reported and this number could be significantly higher.
The document summarizes Arpan Paul's 7-week summer training at JSW Steel's Kalmeshwar plant in India. It includes a certificate certifying his completion of the training. The plant details section describes the plant's production lines including continuous pickling, cold rolling mills, galvanizing, galvalume coating, and color coating lines. It outlines the plant's layout, production portfolio, quality certifications, and department details.
The document summarizes Jindal Steel and Power's integrated steel plant in Angul, Odisha. The key points are:
1) Jindal Steel has invested $6 billion to set up a 12.5 MTPA steel plant and 2,600 MW power plant in Odisha.
2) The first phase is a 6 MTPA steel plant in Angul. A 2.5 MTPA steel melting shop and 1.5 MTPA plate mill have been commissioned.
3) The plant uses DRI-BF-EAF technology and has facilities like a coal washery, sinter plant, and blast furnace to produce steel. The plate mill can produce the widest
This presentation covers all the processes and sub-processes undergoing in the newly installed department in Tata Steel ,i.e., LD3 & TSCR.
This presentation deals with the all the problems faced by this department midway through the process, and mainly focussing on "Bleeding Breakout" problem in TSCR shop.
Also an attempt is made to improve the so-called problem by suggesting certain measures at the end.
Bhilai Steel Plant is a unit of Steel Authority of India Limited (SAIL), which is one of the largest state-owned steel producers in India. The presentation provides an overview of BSP, including its establishment, products, production processes, key departments, and achievements. BSP has an annual production capacity of over 3 million tons and specializes in producing rails, plates, and structural steel. It describes the key production facilities and processes, including the rail and structural mill, plate mill, and steel melting shops. The presentation also outlines some of BSP's certifications and awards it has received for its products, safety, sustainability, and corporate social responsibility efforts.
The document provides an overview of the steel melting shop (SMS) at Jindal Steel and Power Limited (JSPL). It describes the key equipment in the SMS including electric arc furnaces, ladle refining furnaces, vacuum degassing units, and continuous casters. It also summarizes the main processes like primary refining at the electric arc furnace and secondary refining at the ladle refining furnace. Safety rules and precautions for working in the SMS are highlighted at the end.
Study Of Bleeding Breakout In Thin Slab CasterShubham Thakur
This documentation deals with the all the processes and sub-processes undergoing in the newly installed department in Tata Steel ,i.e., LD3 & TSCR, mainly focussing on "Bleeding Breakout" problem in TSCR shop.
The document summarizes key aspects of secondary steelmaking processes. It discusses homogenization through ladle stirring using argon bubbling or electromagnetic stirring. Degassing processes like ladle degassing and circulation degassing are also covered, which are used to remove gases from steel. Other secondary steelmaking stages discussed include heating in the ladle furnace, deoxidation using aluminum, decarburization in vacuum degassing, and desulphurization in the ladle through slag-metal reactions. Injection metallurgy techniques like powder injection and wire feeding are also summarized for adding alloying elements to molten steel.
The document summarizes the steel making process. There are two major commercial processes - basic oxygen steelmaking and electric arc furnace. Basic oxygen steelmaking involves blowing oxygen through molten pig iron to reduce the carbon content and produce steel. Electric arc furnace uses high currents to melt steel scrap and convert it into liquid steel. The document also categorizes different types of steel like carbon steel, alloy steel, stainless steel, and tool steel based on their chemical compositions and applications.
TMT steel is a type of reinforced steel used in concrete structures that undergoes a thermo-mechanical treatment process. This process integrates work hardening and heat treatment into a single step, resulting in bars with excellent corrosion resistance that do not require cold twisting. TMT steel is commonly used in bridges, buildings, dams, and other concrete structures. It has a carbon content of 0.3%, sulfur content of 0.05%, and manganese content of 0.5-1.2%, along with other properties that make it well-suited for concrete reinforcement.
I had done my 2 weeks Vocational Training from Bhilai Steel Plant, Bhilai situated in Chhattisgarh. I am sharing my final internship report which I made for the submission in my University.
This is a practical training of seminar report. In this seminar report all the procedure is include which is use in the industry to how to make a steel and CBRS Department is also include where the engine parts is repair.
This document discusses the process of steel making. It begins by introducing steel and its types, which are classified based on carbon percentage as carbon steel, stainless steel, and alloy steel. It then describes the main steel making methods. The basic oxygen furnace uses carbon-rich pig iron and oxygen to produce low-carbon steel. The electric arc furnace produces specialty steels by heating scrap metal with an electric arc. Secondary steelmaking processes such as argon oxygen decarburization further refine the steel through decarburization, desulphurization, and alloying.
Dear Readers,
In this presentation, I have tried to explain main raw material sources of iron making process. Also, with my experience, I have tried to give a concept about the plant engineering related to raw material. I hope that, this presentation will be helpful for young engineers. With this presentation they will get a broad idea about the raw material, based on which they can study more on the subject.
Regards,
Nirjhar.
Ladle Metallurgy: Basics, Objectives and ProcessesElakkiya Mani
Worldwide steel production in 2019 reached 1869 million tons, with China as the largest producer at 996 million tons. India was the second largest steel producer at 111 million tons. Ladle metallurgy involves further refining of molten steel in a ladle after tapping from a converter or electric furnace. It allows for homogenization, deoxidation, desulfurization, and other processes. Key ladle metallurgy techniques include ladle furnace treatment, argon stirring, vacuum degassing, and alloy additions to adjust steel chemistry and properties.
The document discusses the structure and properties of metallurgical slags. It states that slags comprise complex compounds of oxides from gangue minerals and sulphides that protect the metal melt. The structure and properties of slags, such as basicity and viscosity, are controlled by their composition. Network forming oxides like SiO2 form stable hexagonal networks, while network breaking oxides like CaO disrupt these networks. The fraction of ionic and covalent bonding in oxides determines their behavior in slags.
This document summarizes the process of preparing a tundish for continuous casting of steel. It discusses what a tundish is, the different lining layers including insulation, backup, and working linings. It details the steps to deskull, cool, and apply each lining layer. Key tundish furniture like the submerged entry nozzle and stopper are also described. The final steps of preheating the tundish and attached equipment before use in continuous casting are outlined.
I have done my industrial summer training from Bhilai steel plant which is a unit of SAIL. this is powerpoint presentation of my summer training. it includes all basic knowledge about the plant, process of manufacturing of steel and the factories inside it. you can get to learn new things from this presentation. Thank You !!
This training report summarizes Santosh Kumar's summer training at the Rourkela Steel Plant from May to July 2014. It thanks the employees who supported and guided his training, particularly Mr. Panda and Mr. Patra. The report focused on gaining knowledge about the various processes used at the steel plant, especially in Steel Melting Shop-II.
The blast furnace is an important industrial process used to extract iron from its ore. Raw materials like iron ore, limestone, and coke are input into the blast furnace where a blast of hot air helps coke burn and generates high temperatures to remove oxygen from the iron ore, leaving behind iron. The extracted iron contains impurities that are later removed in the basic oxygen furnace to produce steel.
Continuous casting is a steelmaking process where liquid steel is solidified into a semi-finished billet, bloom, or slab. In this process, liquid steel flows from a ladle into a water-cooled copper mold. As the steel exits the mold, it begins to solidify on the surface while the core remains liquid. The semi-solid steel strand is then cooled further through water sprays to fully solidify it into the desired cross-section. The continuous casting process allows for higher productivity and quality than traditional ingot casting.
Since the 1976 outbreak of Legionnaries’ Disease in Philadelphia, data continues to demonstrate how dangerous Legionella Pneumophila bacteria are to the general public. In 2010, the Center for Disease Control (CDC) reported 3,346 deaths and up to 18,000 hospitalizations were related to Legionella. The CDC also states that there are many infections that are not reported and this number could be significantly higher.
This document provides information about the City & Guilds Level 2 Diploma in Process Technology qualification. It outlines the structure, content, assessment and requirements for both centers and candidates.
The qualification is aimed at those following apprenticeship programs or seeking career progression in process technology industries. It contains core, pathway and optional units focused on subjects like process science, health and safety, process plant operations, and specialized topics depending on the chosen pathway.
Centers must meet approval requirements and ensure staff have appropriate expertise. Candidates do not require formal entry qualifications but centers must ensure they can successfully complete the coursework. Initial assessment is used to identify candidate training and support needs. The handbook provides full details on delivery, assessment,
Engineering-Design-Manufacturing-Assembly of all kind of equipments and services from a single spare parts to complete LF or complete meltshop. Ladles, ladle cars, gas purging stations, emergency lance stirrers, wire feeders, material handling systems, Slab Turnover Device, etc. Training and advisory services. Complete turnkey projects for Mini Steel Plant and rolling mills.
BSP Project (Based on Continuous Casting) [Final]Subham Shit
MARS-2 is a machining, assembly, and re-engineering department of Bhilai Steel Plant. It has light and heavy machining bays and an assembly bay. MARS-2 specializes in machining high-value parts, repairing and reclaiming worn parts, and assembling machinery. Some key assemblies MARS-2 performs include five roll sets, ten roll sets, and pinch roll assemblies for the continuous casting shop. MARS-2 aims to support most departments of BSP. It is well-equipped with machines like lathes, mills, grinders, and has an annual machining capacity of 2,200 tons and assembly capacity of 6,000 tons.
This document discusses the process of continuous casting of steel. It begins with an overview of steel composition and the continuous casting process, which solidifies molten metal directly into final form. Most metals are produced this way, including over 500 million tons of steel annually worldwide. The document then describes the steelmaking processes of basic oxygen furnaces and electric arc furnaces that prepare the molten steel. It focuses on the design, functions, and importance of tundishes in continuous casting, which hold molten steel and facilitate inclusion removal before casting. Key aspects of tundish design like features, insulation, nozzle placement, and refractory lining application are explained.
The document provides an overview of databases and database design. It defines what a database is, what databases do, and the components of database systems and applications. It discusses the database design process, including identifying fields, tables, keys, and relationships between tables. The document also covers database modeling techniques, normalization to eliminate redundant or inefficient data storage, and functional dependencies as constraints on attribute values.
The document discusses various types of casting defects including gas defects, shrinkage cavities, molding material defects, pouring metal defects, and metallurgical defects. It provides detailed descriptions and characteristics of different specific defects such as blowholes, pinhole porosity, cuts and washes, penetration, fusion, rattails, swell, washout, misruns, and cold shuts. The document emphasizes the importance of properly identifying and classifying defects in order to determine their causes and implement appropriate corrective actions to control quality.
This document provides information about dental casting procedures and defects. It discusses the history of casting, outlines the main steps including spruing, investing, burnout and casting. Spruing involves attaching a sprue former made of wax, plastic or metal to direct molten metal into the mold. Investing is the process of enveloping the wax pattern with investment material. Burnout involves slowly heating the mold to eliminate wax. Casting involves melting dental alloys and directing the molten metal into the mold using various casting machines and techniques. The document also discusses potential casting defects.
This document provides information on various metal casting processes. It discusses the history of casting and defines the basic casting process as pouring liquid metal into a mold to solidify. It describes the main features of casting like molds, risers, gates, and cores. It categorizes casting processes as open mold or closed mold casting. It further classifies casting into expandable mold casting like sand casting and investment casting, and permanent mold casting like die casting and centrifugal casting. For each process, it provides details on the mold material, advantages, disadvantages and recommended applications. It emphasizes the importance of selecting the right casting process based on the alloy, shape, tolerance and cost requirements of the final part.
The document discusses the process of sand casting. It begins by defining foundry and casting as the process of producing metal parts by pouring molten metal into a prepared mold. It then provides terminology used in casting such as flask, pattern, parting line, pouring basin, sprue, runner, riser, gate, core, and chaplets. The steps of sand casting are outlined as making the pattern, preparing sand mixtures, making the mold and cores, melting metal, pouring, cleaning, inspecting, and heat treating. Common casting materials and applications are also listed.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive function. Exercise causes chemical changes in the brain that may help protect against developing mental illness and improve symptoms for those who already suffer from conditions like anxiety and depression.
Control of Cooling in Continuous Casting of Thin Steel SlabsBishoy Saeed
This document discusses the development of a digital control system for the secondary cooling process in continuous casting machines used in steel plants. Maintaining the desired temperature is important for optimizing steel quality, as over 96% of steel produced in the US goes through continuous casting. The control system aims to address issues like cracks caused by temperature variations during cooling by setting optimal spray water flow rates, as conventional feedback control cannot rely on temperature sensors. Mathematical models are being developed to predict factors like shell thickness, temperature distribution, and metallurgical length to help with control.
The document provides an overview of Adani Power Limited's thermal power plant located in Mundra, Gujarat, India. It discusses the company history and operations, describes the key components of a typical coal-fired thermal power plant including coal conveyors, stokers, pulverizers, boilers, turbines and more. The Mundra plant has a total installed capacity of 4620 MW produced across four phases, making it one of the largest coal power plants in the world.
The document provides an overview of the history and development of Tata Steel in India from its founding in 1907 up until modern times. It then describes a visit to Tata Steel's Cold Rolling Mill complex, including observations about the cold rolling process, maintenance practices, and electrical systems used. Key developments at Tata Steel include switching to more advanced steelmaking technologies, building new facilities like sinter plants and cold rolling mills, and ongoing improvements to increase efficiency and yields.
This document provides information about Prashant Kumar's vocational training project on the study of CNC machine control systems at Tata Steel in Jamshedpur, India. It includes an acknowledgements section thanking those who supported the project. The document then covers the history and departments of Tata Steel, including Spare Manufacturing Department where the training took place. It provides technical details about CNC machines and their components like PLC, sensors and advantages of CNC systems.
Steel is an alloy of iron and carbon. It is produced by heating iron ore and coal in a blast furnace. There are different types of steel depending on the carbon content, including mild steel (0.15-0.30% carbon), medium carbon steel (0.30-0.80% carbon), and high carbon steel (0.80-1.50% carbon). Alloy steels have additional elements added like chromium, nickel, or molybdenum to improve properties. Common alloy steels are stainless steels, heat resisting steels, and high speed steels. Cast iron is also an iron-carbon alloy but with more carbon (2-4.3%). The main types
The document provides information about the history and modern processes of steel production. It discusses how steel is made by heating iron ore along with coke and limestone in a blast furnace. The liquid iron is then processed in basic oxygen furnaces or electric arc furnaces to produce steel by adding other elements like carbon. Steel can be continuously cast into specific shapes or made into ingots. The steel undergoes additional processing like machining before final inspection and packaging for shipping.
Alloy steel is steel that contains other alloying elements in addition to carbon. Common alloying elements include manganese, nickel, chromium, molybdenum, vanadium, silicon, and boron. Alloy steel has improved properties over carbon steel such as higher tensile strength, hardness, toughness, wear resistance, creep resistance, and high temperature resistance. These properties make alloy steel suitable for applications in automotive, engineering, construction, agriculture, home goods, and military uses. Production of alloy steel has been increasing to meet the demands of growing industries such as automotive and engineering.
Can you write a report about steel.In your report you need to includ.pdfAmansupan
Can you write a report about steel.In your report you need to include the types of steel,the
manufacturing process of steel,the application of steel in construction and also the advantages
and disadvantages of steel.You need to write your answer neatly so that I can see and understand
it easily.
Solution
INTRODUCTION
Steel is an alloy of iron and other elements, primarily carbon, that is widely used in construction
and other applications because of its high tensile strength and low cost. Steel\'s base metal is
iron, which is able to take on two crystalline forms (allotropic forms), body centered cubic
(BCC) and face centered cubic (FCC), depending on its temperature. , it’s one of the most
popular metals in fabrication shops.
TYPES OF STEEL
1) Carbon Steels:
Carbon steels contain trace amounts of alloying elements and account for 90% of total steel
production. Carbon steels can be further categorized into three groups depending on their carbon
content:
2) Alloy Steels:
Alloy steels contain alloying elements (e.g. manganese, silicon, nickel, titanium, copper,
chromium and aluminum) in varying proportions in order to manipulate the steel\'s properties,
such as its hardenability, corrosion resistance, strength, formability, weldability or ductility.
Applications for alloys steel include pipelines, auto parts, transformers, power generators and
electric motors.
3) Stainless Steels:
Stainless steels generally contain between 10-20% chromium as the main alloying element and
are valued for high corrosion resistance. With over 11% chromium, steel is about 200 times more
resistant to corrosion than mild steel. These steels can be divided into three groups based on their
crystalline structure:
4) Tool Steels:
Tool steels contain tungsten, molybdenum, cobalt and vanadium in varying quantities to
increase heat resistance and durability, making them ideal for cutting and drilling equipment.
2) Deformed steel bars
Mild steel bars are used for tensile stress of RCC (Reinforced cement concrete) slab beams etc.
in reinforced cement concrete work. These steel bars are plain in surface and are round sections
of diameter from 6 to 50 mm. These rods are manufactured in long lengths and can be cut
quickly and be bent easily without damage.
As deformed bars are rods of steels provided with lugs, ribs or deformation on the surface of bar,
these bars minimize slippage in concrete and increases the bond between the two materials.
Deformed bars have more tensile stresses than that of mild steel plain bars. These bars can be
used without end hooks. The deformation should be spaced along the bar at substantially uniform
distances.
To limit cracks that may develop in reinforced concrete around mild steel bars due to stretching
of bars and some lose of bond under load it is common to use deformed bars that have projecting
ribs or are twisted to improve the bond with concrete. These bars are produced in sections from 6
mm to 50 mm dia.
In addition the strength of bonds of d.
Steel is an alloy of iron and carbon, and sometimes other elements like manganese and chromium. It is a strong, hard material widely used in construction. Steel has high strength, is lightweight, elastic, ductile, and dimensionally stable. It can be used to build tall skyscrapers. Some disadvantages are that steel requires maintenance to prevent corrosion and fireproofing to maintain strength at high temperatures.
Nishant Ranjan completed a summer training project at Tata Steel's Spares Manufacturing Department studying the electrical furnace in the heat treatment shop and the power system of the west plant substation. The project report acknowledges the support received from Tata Steel employees including the foreman of the heat treatment shop and the manager of the spares manufacturing department who guided the project. The certification section confirms Nishant successfully completed the project during his summer training from June 3-28, 2014.
Electrical furnace and Substation at Tata Steelnishantrj
The document discusses heat treatment processes used at Tata Steel's Spares Manufacturing Department. It describes the department's various shops including forging, heat treatment, welding, fabrication, and machine shops. It provides details on the BOFCO Tempering Machine, an electrical furnace used for hardening, quenching, tempering, and other heat treatment processes. Processes like hardening, annealing, normalizing and tempering are explained. Gas and electrical furnaces at the heat treatment shop are also summarized.
The document discusses the iron and steel industry in Pakistan. It describes the raw materials used like iron ore, manganese, coking coal and limestone. It explains the steel making process which involves heating iron ore and coke in a blast furnace. The main outputs are steel billets, hot rolled products, cold rolled sheets and galvanized products. Pakistan Steel Mills is located in Karachi for its access to raw materials through the port and energy resources. Over half of its steel output is sent to Punjab for industrial use. The industry faces environmental issues from pollution and economic challenges due to import dependence.
The document discusses the iron and steel industry in Pakistan. It describes the raw materials used like iron ore, manganese, coking coal and limestone. It explains the steel making process which involves heating iron ore and coke in a blast furnace. The main outputs are steel billets, hot rolled products, cold rolled sheets and galvanized products. Pakistan Steel Mills is located in Karachi for its access to raw materials from ports and markets in Punjab for over half its production. The industry faces environmental issues from pollution and economic challenges from relying on imports.
Steelmaking and Iron Products (Cast Iron, Compacted Graphite Irons, Ductile I...Ajjay Kumar Gupta
The iron and steel industry is one of the most important industries in India. Most iron and steel in India is produced from iron ore. The Indian Ministry of Steel is concerned with: the coordination and planning of the growth and development of the iron and steel industry in the country, both in the public and private sectors; formulation of policies with respect to production, pricing, distribution, import and export of iron and steel, Ferro alloys and refractories; and the development of input industries relating to iron ore, manganese ore, chrome ore and refractories etc., required mainly by the steel industry.
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Steel is an alloy of iron and carbon that is strong yet affordable, making it widely used in construction. It has a long history dating back thousands of years. There are many types of steel classified by composition and manufacturing process. Steel is made through heating iron ore with coke in a blast furnace, then further processed. It is strong but vulnerable to fire. Its major uses are in buildings, infrastructure, transportation, appliances, packaging, and energy projects due to its strength and versatility.
Industrial Training Report on Steel Melting Shop(SMS)Shani Kumar Singh
1. The document provides an overview of Jindal Steel and Power Limited (JSPL), describing its facilities, products, and status as one of India's largest steel producers.
2. It then summarizes the steel melting shop (SMS) process, which involves primary and secondary steelmaking using equipment like electric arc furnaces, ladle refining furnaces, and continuous casters to produce high quality steel from raw materials.
3. Key equipment in the SMS plant are described briefly, including the electric arc furnace, ladle refining furnace, vacuum degassing unit, and various continuous casters.
Steel is an alloy of iron with carbon, along with other elements. It has high tensile strength and low cost, making it useful for buildings, infrastructure, tools, vehicles, appliances, and more. Mild steel contains less than 0.25% carbon. Stainless steel contains at least 10% chromium and 8% nickel. Common uses of steel include construction, vehicles, machinery, and packaging. The construction industry is a major consumer of steel.
Steelmaking, Shaping, Treating and Processing, Steel and Steel Products (Fast...Ajjay Kumar Gupta
Steel is one of the most important and widely used products in the world. Currently, the steel industry is undergoing a process of change. As a result of ongoing technical and economic developments, the production and use of electric arc furnace steel is, beneath the steel production in a blast furnace, becoming increasingly important, continuously gaining share of world-wide steel production over the past 30 years.
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Bolt and Nut Manufacturing Technology, Business guidance for steel production industry, Business plan for steel rolling mill, Casting, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot Rolling Mill, Hot rolling mill process, Hot Rolling mill, Hot Rolling of Plate, Sheet and Strip, Hot Seamless Tube Rolling Processes, Hot Strip Mill, How is Steel Produced?, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Iron and Steel making by-Products, Manufacturing of Steel, Manufacturing Process for Steel products, Metal Fasteners Manufacturing, Mill Automation for Pipe and Tubing Production, Modern Rolling Plant, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Production of Welded Pipe, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Rod and Bar Rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling of Flat Products & others, Rolling of Steel, Bars and Rods, Rolling process, Seamless Tubes manufacturing, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel production Business, Starting Steel Mini Mill, Start-up Business Plan for steel products manufacturing, Startup Project for steel making business, Steel and hot rolling Business, Steel and Steel Products, Steel Based Profitable Projects, Steel Based Small Scale Industries Projects, Steel business opportunities, Steel Making, Steel making and Refining, Steel Making Products and Processes, Steel making Projects, Steel making technology, Steel manufacture, Steel mill process, Steel Production, Steel Production Process and Products, Steel Products Business, Steel Products for the Building Trade, Steel products manufacturing process, Steel rerolling mill feasibility start up, Steel rolling Industry in India, Steel rolling machine factory, Steel Rolling Technology, Steelmaking Processes, Steelmaking, Shaping, Treating and Processing, Types of rolling mills, Varnishing and Printing of Packaging Steels
Introduction to modern concept of steel making through induction furnaces by ...steadfast123
Introduction to modern concept of steel making through induction furnaces by stead fast engineers.Find here
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for your sourcing needs.
1. Ferrous metals like cast irons and steels are extracted from raw materials through efficient and cleaner methods.
2. This leads to industrial growth through new manufacturing industries and improved infrastructure like power, transport, and communication.
3. Living standards of people improve as technical education increases skilled labor, improving salaries and national economic output.
Electric vehicle and photovoltaic advanced roles in enhancing the financial p...IJECEIAES
Climate change's impact on the planet forced the United Nations and governments to promote green energies and electric transportation. The deployments of photovoltaic (PV) and electric vehicle (EV) systems gained stronger momentum due to their numerous advantages over fossil fuel types. The advantages go beyond sustainability to reach financial support and stability. The work in this paper introduces the hybrid system between PV and EV to support industrial and commercial plants. This paper covers the theoretical framework of the proposed hybrid system including the required equation to complete the cost analysis when PV and EV are present. In addition, the proposed design diagram which sets the priorities and requirements of the system is presented. The proposed approach allows setup to advance their power stability, especially during power outages. The presented information supports researchers and plant owners to complete the necessary analysis while promoting the deployment of clean energy. The result of a case study that represents a dairy milk farmer supports the theoretical works and highlights its advanced benefits to existing plants. The short return on investment of the proposed approach supports the paper's novelty approach for the sustainable electrical system. In addition, the proposed system allows for an isolated power setup without the need for a transmission line which enhances the safety of the electrical network
Redefining brain tumor segmentation: a cutting-edge convolutional neural netw...IJECEIAES
Medical image analysis has witnessed significant advancements with deep learning techniques. In the domain of brain tumor segmentation, the ability to
precisely delineate tumor boundaries from magnetic resonance imaging (MRI)
scans holds profound implications for diagnosis. This study presents an ensemble convolutional neural network (CNN) with transfer learning, integrating
the state-of-the-art Deeplabv3+ architecture with the ResNet18 backbone. The
model is rigorously trained and evaluated, exhibiting remarkable performance
metrics, including an impressive global accuracy of 99.286%, a high-class accuracy of 82.191%, a mean intersection over union (IoU) of 79.900%, a weighted
IoU of 98.620%, and a Boundary F1 (BF) score of 83.303%. Notably, a detailed comparative analysis with existing methods showcases the superiority of
our proposed model. These findings underscore the model’s competence in precise brain tumor localization, underscoring its potential to revolutionize medical
image analysis and enhance healthcare outcomes. This research paves the way
for future exploration and optimization of advanced CNN models in medical
imaging, emphasizing addressing false positives and resource efficiency.
Batteries -Introduction – Types of Batteries – discharging and charging of battery - characteristics of battery –battery rating- various tests on battery- – Primary battery: silver button cell- Secondary battery :Ni-Cd battery-modern battery: lithium ion battery-maintenance of batteries-choices of batteries for electric vehicle applications.
Fuel Cells: Introduction- importance and classification of fuel cells - description, principle, components, applications of fuel cells: H2-O2 fuel cell, alkaline fuel cell, molten carbonate fuel cell and direct methanol fuel cells.
An improved modulation technique suitable for a three level flying capacitor ...IJECEIAES
This research paper introduces an innovative modulation technique for controlling a 3-level flying capacitor multilevel inverter (FCMLI), aiming to streamline the modulation process in contrast to conventional methods. The proposed
simplified modulation technique paves the way for more straightforward and
efficient control of multilevel inverters, enabling their widespread adoption and
integration into modern power electronic systems. Through the amalgamation of
sinusoidal pulse width modulation (SPWM) with a high-frequency square wave
pulse, this controlling technique attains energy equilibrium across the coupling
capacitor. The modulation scheme incorporates a simplified switching pattern
and a decreased count of voltage references, thereby simplifying the control
algorithm.
Optimizing Gradle Builds - Gradle DPE Tour Berlin 2024Sinan KOZAK
Sinan from the Delivery Hero mobile infrastructure engineering team shares a deep dive into performance acceleration with Gradle build cache optimizations. Sinan shares their journey into solving complex build-cache problems that affect Gradle builds. By understanding the challenges and solutions found in our journey, we aim to demonstrate the possibilities for faster builds. The case study reveals how overlapping outputs and cache misconfigurations led to significant increases in build times, especially as the project scaled up with numerous modules using Paparazzi tests. The journey from diagnosing to defeating cache issues offers invaluable lessons on maintaining cache integrity without sacrificing functionality.
Null Bangalore | Pentesters Approach to AWS IAMDivyanshu
#Abstract:
- Learn more about the real-world methods for auditing AWS IAM (Identity and Access Management) as a pentester. So let us proceed with a brief discussion of IAM as well as some typical misconfigurations and their potential exploits in order to reinforce the understanding of IAM security best practices.
- Gain actionable insights into AWS IAM policies and roles, using hands on approach.
#Prerequisites:
- Basic understanding of AWS services and architecture
- Familiarity with cloud security concepts
- Experience using the AWS Management Console or AWS CLI.
- For hands on lab create account on [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
# Scenario Covered:
- Basics of IAM in AWS
- Implementing IAM Policies with Least Privilege to Manage S3 Bucket
- Objective: Create an S3 bucket with least privilege IAM policy and validate access.
- Steps:
- Create S3 bucket.
- Attach least privilege policy to IAM user.
- Validate access.
- Exploiting IAM PassRole Misconfiguration
-Allows a user to pass a specific IAM role to an AWS service (ec2), typically used for service access delegation. Then exploit PassRole Misconfiguration granting unauthorized access to sensitive resources.
- Objective: Demonstrate how a PassRole misconfiguration can grant unauthorized access.
- Steps:
- Allow user to pass IAM role to EC2.
- Exploit misconfiguration for unauthorized access.
- Access sensitive resources.
- Exploiting IAM AssumeRole Misconfiguration with Overly Permissive Role
- An overly permissive IAM role configuration can lead to privilege escalation by creating a role with administrative privileges and allow a user to assume this role.
- Objective: Show how overly permissive IAM roles can lead to privilege escalation.
- Steps:
- Create role with administrative privileges.
- Allow user to assume the role.
- Perform administrative actions.
- Differentiation between PassRole vs AssumeRole
Try at [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
Applications of artificial Intelligence in Mechanical Engineering.pdfAtif Razi
Historically, mechanical engineering has relied heavily on human expertise and empirical methods to solve complex problems. With the introduction of computer-aided design (CAD) and finite element analysis (FEA), the field took its first steps towards digitization. These tools allowed engineers to simulate and analyze mechanical systems with greater accuracy and efficiency. However, the sheer volume of data generated by modern engineering systems and the increasing complexity of these systems have necessitated more advanced analytical tools, paving the way for AI.
AI offers the capability to process vast amounts of data, identify patterns, and make predictions with a level of speed and accuracy unattainable by traditional methods. This has profound implications for mechanical engineering, enabling more efficient design processes, predictive maintenance strategies, and optimized manufacturing operations. AI-driven tools can learn from historical data, adapt to new information, and continuously improve their performance, making them invaluable in tackling the multifaceted challenges of modern mechanical engineering.
Applications of artificial Intelligence in Mechanical Engineering.pdf
Vinay kumar
1. 1 | P a g e
A
PROJECT REPORT
ON
“Eliminating corner gap in sc mould at LD2
SNC”
SUBMITTED BY:
Vinay kumar
B.Tech
Machenical Engineering
B.A. College of Engg & Tech.
Jamshedpur.
GUIDED BY:
Mr.Shaswat Anand
Manager-segment shop
2. 2 | P a g e
APPROVAL CERTIFICATE
The foregoing project report entitled “Elimnating corner gap in sc
mould at LD2 SNC” submitted by Mr. Vinay kumar (Summer Intern
‘15 )is hereby approved as authentic study of his Project work
during his vocational training at Tata Steel, Jamshedpur.
It is presented in satisfactory manner to warrant its acceptance as a
prerequisite in the completion of his vocational training.
GUIDE
Mr. Shaswat Anand
Manager-Segment Shop
4. 4 | P a g e
ACKNOWLEDGEMENT
Any accomplishment, big or small, has a number of persons behind
the scene and I must acknowledge that this project was no
exception.
First of all I would like to convey my gratitude to my guide Mr.
Shaswat Anand (Manager-segment shop) for his continuous
support during my project. He has been a constant source of
encouragement during the entire project. He provided me valuable
information as well as knowledge regarding my project. I
Finally, I would like to convey a word of thanks to “ TATA STEEL”
administration for providing me this great opportunity to undergo
my summer internship under its esteemed banner.
5. 5 | P a g e
TATA STEEL
An Introduction
Established in 1907, Tata Steel is the world’s 6th largest steel
company with an
Existing annual crude steel capacity of 28MTPA. Asia’s first
integrated steel plant& India’s largest integrated private sector steel
company is now the world’s second most geographically diversified
steel producer, with operations in 24countries &commercial
presence in over 50 countries .Tata steel completed 100years of
existence on August 26, 2007 following the ideals & philosophy laid
down by its Founder , JAMSETJI NUSSERWANJI TATA. The first
private sector steel plant which started with a production capacity
of 1, 00,000 tones has transformed into a global giant.
J.N.Tata-The Founder An overview of TATA STEEL
Tata Steel plans to grow & globalize through organic & inorganic
routes. Its 6.08MTPA Jamshedpur works plans to 10MTPA capacity
by 2012. The company also has three Greenfield steel projects in
the states of Jharkhand, Orissa &Chhattisgarh and proposed steel
making facilities in Vietnam and Bangladesh.
Through investments in Corus , Millennium Steel { Renamed Tata
Steel Thailand }and NatSteel Asia , Singapore , the Tata steel has
created a manufacturing and marketing network in Europe , South
6. 6 | P a g e
East Asia and the Pacific- rim countries. Corus, which
manufactured 18.3 MT of steel in 2006, has operations in the UK,
the Netherlands, Germany, France, Norway &Belgium. Tata Steel
(Thailand) is the largest producer of long steel products in Thailand,
with a manufacturing capacity of 1.7 MT. NatSteel Asia produces
about 2 MT of steel products annually across its regional operations
in seven countries. Tata Steel through its joint venture with Tata
Blue Scope Steel limited has also entered the steel building and
construction applications market.
The iron ore ones & collieries in India give the company a distinct
advantage in raw material sourcing. Tata steel is also striving
towards raw materials security through joint ventures in Thailand,
Australia, Mozambique, Ivory Coast (West Africa) and Oman.
Tata Steel’s vision is to be the global steel industry benchmark for
“Value Creation and Corporate Citizenship”.
Process Flow At Tata Steel
7. 7 | P a g e
SNTI (Shavak Nanavati Technical
Institute)
• SNTI (Shavak Nanavati Technical Institute) the erstwhile
Jamshedpur technical institute, was established in the year
1921 to provide the technically qualified human resource for
Tata Steel.
• It was the inspiration of the founder of TISCO, “Let the
Indians learn to do things by themselves” , which came into
reality by the establishment of the institute.
• Today SNTI form an integral part of the HR management
division of TATA STEEL.
• It has rendered commendable service in nation development of
technical manpower not only for Tata Steel, but also for the
steel plants in the public sector and other manufacturing
industries.
8. 8 | P a g e
What is steel?
Steel is a compound of iron and carbon. Modern steels also use
traces of magnesium, chromium, tungsten, molybdenum,
manganese, nickel and cobalt. All of these can be used to varying
degrees to help make the steel harder, lighter, more or less resistant
to heat and electrical current, more ductile and corrosion resistant.
Steels are a large family of metals. All of them are alloys in which
iron is mixed with carbon and other elements. Steels are described
as mild, medium- or high-carbon steels according to the percentage
of carbon they contain, although this is never greater than about
1.5%.
Steel is an alloy of iron and other elements, including carbon.
When carbon is the primary alloying element, its content in the steel
is between 0.002% and 2.1% by weight. The following elements are
always present in steel:
carbon, manganese, phosphorus, sulfur, silicon, and traces
of oxygen, nitrogen and aluminum. Alloying elements intentionally
added to modify the characteristics of steel include:
manganese, nickel, chromium, molybdenum, boron, titanium, vana
dium and niobium.[1]
Carbon and other elements act as a hardening agent,
preventing dislocations in the iron atom crystal lattice from sliding
past one another. Varying the amount of alloying elements and the
form of their presence in the steel (solute elements, precipitated
phase) controls qualities such as the hardness, ductility, and tensile
strength of the resulting steel. Steel with increased carbon content
can be made harder and stronger than iron, but such steel is also
less ductile than iron.
Alloys with a higher than 2.1% carbon (depending on other element
content and possibly on processing) are known as cast iron.
Because they are not malleable even when hot, they can be worked
only by casting, and they have lower melting point and
good castability.[1] Steel is also distinguishable from wrought iron,
which can contain a small amount of carbon, but it is included in
the form of slag inclusions.
9. 9 | P a g e
Though steel had been produced in a blacksmith's forge for
thousands of years, its use became more extensive after more
efficient production methods were devised in the 17th century. With
the invention of the Bessemer process in the mid-19th century,
steel became an inexpensive mass-produced material. Further
refinements in the process, such as basic oxygen
steelmaking (BOS), lowered the cost of production while increasing
the quality of the metal. Today, steel is one of the most common
materials in the world, with more than 1.3 billion tons produced
annually. It is a major component in buildings, infrastructure, tools,
ships, automobiles, machines, appliances, and weapons. Modern
steel is generally identified by various grades defined by
assorted standards organizations.
What is steel production?
When iron is smelted from its ore by commercial processes, it
contains more carbon than is desirable. To become steel, it must be
melted and reprocessed to reduce the carbon to the correct amount,
at which point other elements can be added. This liquid is
then continuously cast into long slabs or cast into ingots.
Approximately 96% of steel is continuously cast, while only 4% is
produced as ingots.[12]
The ingots are then heated in a soaking pit and hot rolled into
slabs, blooms, or billets. Slabs are hot or cold rolled into sheet
metal or plates. Billets are hot or cold rolled into bars, rods, and
wire. Blooms are hot or cold rolled into structural steel, such as I-
beams and rails. In modern steel mills these processes often occur
in one assembly line, with ore coming in and finished steel coming
out.[13] Sometimes after a steel's final rolling it is heat treated for
strength, however this is relatively rare
Iron ore pellets for the production of steel.
10. 10 | P a g e
How a steel plant work ?
A plant has many needs for it to grow. The most important are:
Carbon, hydrogen and oxygen Nitrogen, phosphorus, potassium
Sulfur, calcium, and magnesium
The most important of these
are nitrogen, phosphorus and potassium. Nitrogen, phosphorus
and potassium are important because they are necessary for
these basic building blocks. For example: Every molecule making
up every cell's membrane contains phosphorous. Potassium
makes up 1 percent to 2 percent of the weight of any
plant.Without these tree items, the plant could not grow because
it can't make the pieces it needs. In nature, the nitrogen,
phosphorous and potassium often come from the decay of plants.
Steel is an alloy of iron and carbon. It is produced in a two-stage
process. First, iron
ore is reduced or smelted with coke and limestone in a blast
furnace, producing molten iron which is either cast into pig
iron or carried to the next stage as molten iron. In the second
stage, known as steelmaking, impurities such
as sulfur, phosphorus, and excess carbon are removed
and alloying elements such
asmanganese, nickel, chromium and vanadium are added to
produce the exact steel required. Steel mills then turn molten
steel into blooms, ingots, slabs and sheet through casting, hot
rolling and cold rolling.
How is steel produce?
There are two types of metals, ferrous & non-ferrous. Ferrous comes
from, or contains iron, while Non-Ferrous does not contain iron.
Some examples of ferrous metals would be mild steel, cast iron,
high strength steel, and tool steels.
Examples of non-ferrous metals would be copper, aluminum,
magnesium, titanium, etc.
11. 11 | P a g e
To make steel, iron ore is first mined from the ground. It is then
smelted in blast furnaces where the impurities are removed and
carbon is added. In fact, a very simple definition of steel is "iron
alloyed with carbon, usually less than 1%."
The following text is taken from the Structural Manual For
Ironworkers Manual V-Volume I.
Blast furnaces require many auxiliary facilities to support their
operations. However, in simplest terms, the furnace itself is a huge
steel shell almost cylindrical in shape and lined with heat-resistant
brick. Once started, or "blown-in," the furnace operates
continuously until the refractory lining needs renewal or until
demand for iron drops to the point where the furnace is closed
down. The duration of furnace operations from start to finish is
referred to as a "campaign" and may last several years.
Iron ore and other iron bearing materials, coke and limestone are
charged into the furnace from the top and work their way down,
becoming hotter as they sink in the body of the furnace which is
called the stack. In the top half of the furnace, gas from burning
coke removes a great deal of oxygen from the iron ore. About
halfway down, limestone begins to react with impurities in the ore
and the coke to form a slag.
Ash from the coke is absorbed by the slag. Some silica in the ore is
reduced to silicon and dissolves in the iron as does some carbon in
the coke. At the bottom of the furnace where temperatures rise well
over 3000 Fahrenheit, molten slag floats on a pool of molten iron
which is four or five feet deep. Because the slag floats on top of the
iron it is possible to drain it off through a slag notch in the furnace.
The molten iron is released from the hearth of the furnace through a
tap hole. The tapping of iron and slag is the major factor permitting
additional materials to be charged at the furnace top.
This brief summary of the complex operations of a blast furnace is
presented here to provide a point of reference for the actual flow of
operations. Very often, several blast furnaces may be arranged in a
single plant so that the most efficient possible use can be made of
fuels, internal rail facilities, etc
12. 12 | P a g e
2.0) MATERIAL HANDLING PROCESS AT TATA
STEEL
Under 3.0MTPA Expansion Projectof Tata Steel the following
facilities have been installed at Jamshedpur works in addition to its
present operations:
1.0) Pellet Plant 6.0MTPA: Produces pellets for Blast Furnace
2.0) Blast Furnace 3.0 MTPA: Produces pig iron from
Ore/Sinter/Pellet,
and Coke & PCI Coal
3.0) Coke Oven Battery: Produces coke from coal for Blast Furnace
4.0) Lime Kilns#8&9: Produces lime from lime stone for LD#3
5.0) LD#3: Produces steel from pig ironand uses lime
The following basic raw materials are required for operation of above
plants.
1. Blast Furnace – Coke, Sinter, Ore/additives, Pellet and PCI
coalCoke Ovens – Coal
2. Lime Calcining Plant – Lime stone,
3. Pellet Plant – Iron ore fines,
4. LD: Lime and additives
In order to handle huge amount of several varieties of raw materials
for above production units, Tata Steel has installed fully automated
bulk material handling system. This document outlines the study of
material handling process and the associated automation systems
for operation of Raw Material Handling systems.
Primarily raw material handling process broadly covers the following
activities:
1. Raw materials receiving from various sources thru rail/road
2. Unloading of incoming raw materials
3. Transfer of raw materials from unloading points to
storage/stock pile yards
4. Stock piling of materials
13. 13 | P a g e
5. Reclaiming anddistribution of raw materials from storage/stock
piles
thru conveying system to consuming production plants
The automation system associated with materials handling system
ensures safe and energy efficient handling of materials in desired
quantities as per requirements by the production units without any
losses or with minimum losses.
The Material handling system consists the following major
equipment:
1 Weigh bridges 13 Belt Feeders
2 Track hoppers 14 Weigh Feeders
3 Plough feeders 15 Vibrating Feeders
4 Wagon Tippler 16 Vibrating Screens
5 Apron feeder 17 Surge hoppers
6 Stacker cum
reclaimer
18 Reversible
Conveyors
7 Bucket wheel
stacker cum
reclaimer
19 Reversible shuttle
conveyor
8 Traveling Tipper 20 Reversible hammer
mill
9 Conveyors 21 Double roll coke
crusher
10 Magnetic
separators
22 Twin Boom Stacker
11 Bucket wheel on
boom reclaimer
23 Barrel Reclaimer
12 Bins
The operations of the above equipment are fully controlled by using
PLC’s (Programmable Logic Controllers) and facilitate remote
operations from control rooms.
Apart from PLC automation, there are several other systems
facilitate safe operation of the handling process in auto.
1. Electrical motors/drives
2. Safety switches
14. 14 | P a g e
3. Metal detectors
4. Magnetic Separators
5. Belt Scales
6. CCTV monitoring
7. Fire Detection and Alarm systems
8. Communication systems
Among all material handling equipment, the conveying system plays major role to
transfer the bulk raw materials from one place to other. The conveying system
used in Tata Steel is elaborated further
LD SHOP DESCRIPTION
• The LD shop takes in Hot metal from the blast furnace and
refine them so that it can be turned into refined steel before
being cast into billets and slabs depending on the
requirements.
• In Tata Steel there are presently LD#1, LD#2, LD#3 and TSCR
departments for the above mentioned process.
LD#2 Shop
The main units of LD#2 Shop are:-
1). Hot metal receiving and Handling
2). Desulphurization
3). Basic oxygen furnace
4). Online purging
5). Ladle furnace
6).RH degasser
7). Gas cleaning plant
8).Secondary emission plant
15. 15 | P a g e
LD#2 Shop Process
The hot metal is received in the torpedo pits of the LD shop
via torpedo (capacity is 200T to 320T) from the blast
furnace.
The metal received is crude in terms of the composition
and needed to be further refined.
The first step in LD#2 shop is DESULPHURIZATION
process, the Sulphur content is controlled in this process.
The desulphurization process takes place in the D.S unit
where calcium carbide and magnesium are used to and the
sulphur is brought down to the target level depending on
the grade requirements.
The next step is the BOF process. This is the most widely
used steel refining process and this was first introduced in
the towns of Linz and Donowitz and hence the name LD.
In the LD converter Oxygen is blown from the top of the
converter to reduce the carbon content also various
additives like fluxes, Ferro alloys and scrap is added to
stabilize the process and to produce the required grade of
Steel. The metal obtained is called “Primary Refined Steel”
16. 16 | P a g e
The steel after refining in the BOF is tapped and is sent to
the Ladle furnace where the trimming additions takes place
to fine tune the steel compositions.
In the ladle furnace the molten steel is heated by means of
electrode to maintain temperature wire feeding system for
Ferro alloy.
From the ladle furnace the steel is sent to the caster for
casting into billets or slabs.
In certain cases where high quality and cleanliness is
required the steel is sent t the RH(Ruhrstahl -Heraeus)
facility which is a vacuum degassing unit to further reduce
carbon, oxygen, nitrogen and hydrogen content.
Overview of LD2 & Slab Caster 1.
17. 17 | P a g e
LD-2
Supplied by S.N. Portugal of Portugal LD 2 was commissioned in 1993.
With two BOF vessels from VAI, the plant has a rated capacity of 1.10
million tonnes. Hot metal is supplied in 200 t nominal capacity torpedo
ladles from the blast furnaces. The metal is poured into 150 t transfer
ladles at the hot metal pouring pit .The hot metal in the transfer ladle is
desulphuriser at the desulphurization unit after removing the slags and
thereafter, taken to the converters.
The details of hot metal handling system are:
: The input Hot Metal comes from Furnaces A,
B, C, D, F, G, H & I in torpedo ladles of 220tons.
: Hot Metal from Torpedo is transferred to ordinary
Transfer Ladle of 150tons capacity by tilting the Torpedo. From 2
torpedoes we get metal for three heats.
: Initially BF Slag is raked of with the
help of raking machine. Then desulphurisation starts with the injection
of CaC2 & Mg injection through refractory lance with Nitrogen as the
carrier gas. The lance dips inside the metal and injection starts. Sulphur
of the hot metal removes in the form of CaS & MgS and floats up. This is
raked off. The time of DS depends on the initial ‘S’ content of the hot
metal & the final product specification required.
: The 3 BOF vessels have been supplied by SMS Demag. Pig
iron in the transfer ladle is taken inside the BOF vessels for controlled
oxidation using lance heater. At this stage additives are added to prepare
the required blend of steel. Inert gas, Argon is blown in order to maintain
the uniformity of the hot metal.
Lance heater used for oxidation contains 3 concentric flow paths.
The centre flow path is used for blowing oxygen into the vessel and the
other 2 flow paths are used to water cooling of lance.
At the time of oxidation, the lance goes deep into the vessel so that
uniform oxidation can take place. Slag formation takes place in the upper
part of the vessel whereas molten steel in produced in the lower part.
Slag is removed by tilting the vessel from the top of the vessel into a ladle
transfer car below and the steel is poured into another ladle below it from
the neck opening of the vessel by tilting it in opposite direction.
18. 18 | P a g e
Steel in the ladle now is taken for further secondary metallurgical
processing in SMLP (Secondary Metallurgical Ladle Processing) shop
mentioned below.
: Different routes of steel making are mentioned
below:
Converter-Caster(30-35% Heats)
Converter-RH-Caster(18-20% Heats)
Converter-LF-Caster(50-55% Heats)
Converter-LF-RH-Caster(6-8% Heats)
: The process was developed by Rheinstahl Heinrich in
1957. The process in named after him. In order to produce steel for high-
end applications, liquid steel is routed through. This degassing unit in
which treatment takes place under vacuum.
The degassing chamber is a cylindrical steel shell with two legs called
snorkels and the openings at the top side are provided for exhaust, alloy
additions, observations and control. During degassing metal enters the
cylindrical vacuum chamber through one snorkel and flows back under
gravity through other. The chamber is lifted and lowered to an
appropriate level in the ladle containing molten steel. The chamber is
evacuated and the molten steel just rises in the chamber. The
atmospheric pressure causes the molten steel to rise above the, still bulk
level, in the snorkel, under deep vacuum. Lift gas like argon is then
introduced in the inlet snorkel which expands and rises up thereby
raising the velocity of steel in the inlet snorkel. The net result of this is
that degassing takes place very efficiently. Gravity causes steel to flow
back in the ladle via the other snorkel. Degassed steel is slightly cooler
and denser than in the ladle and hence it forces the lighter undegassed
steel upwards thereby ensuring adequate mixing and homogeneity. At
the end of the process alloy additions may be made depending upon the
superheat available in the steel.
: Liquid steel from the converter is tapped into
preheated ladles and then treated at the ladle furnace for
homogenization, increase of temperature and for trimming additions are
done. It is a simple ladle like furnace provided with bottom plug for argon
19. 19 | P a g e
purging and lid with electrodes to become an arc furnace for heating the
bath. Another lid may be provided to connect it to vacuum line, if
required. Chutes are provided for additions and an opening even for
injection. It is capable of carrying out stirring, vacuum treatment,
synthetic slag refining, plunging, injection etc. all in one unit without
restraint of temperature loss, since it is capable of being heated
independently.
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2. Slab Caster
There are three single strands continuous casting machine which have
been specifically designed to cast high quality slabs suitable for hot
charging to the Hot Strip. The main machine at LD#2 and Slab Caster
was modified to include a new vertical mould and Bender/Straightener
Segments, up gradation of ladle turret, modification of the Tundish. Car
and existing segments, augmentation of hydraulic systems including pipe
work, instrumentation & automation system and numerous attendant
changes for the Company to manufacture more demanding grades of
steel.
The slab casting machine has been specifically designed to cast high
quality slabs at higher yield, low cost and high productivity.
The machine is equipped to cast 215mm thick and 800-1550mm wide
slabs. No.1 caster is vertical mould caster and other two are curved
mould caster. Each bender strand has mould and a radius of 10m with a
support length of 29.75m. The vertical caster has a radius of 7.5m over
this length this slab is initially supported by mould followed by cooling
grids and then top and bottom rollers during solidification. The partly or
fully solidified curved slab is removed by continuous straightening
method prior to withdrawal and final solidification. Hot metal for casting
is supplied from converters via secondary steel making facilities. The
22. 22 | P a g e
charged ladle with steel in its optimum state is transported to position.
As the turret is rotated, the Tundish is driven over the mould from its
pre-heat station by a Tundish car. Ladle shroud is then fixed for
shrouding of ladle to Tundish stream. Once all “ready to cast” interlocks
are healthy, casting is started.
The mould is mounted on pivot arms supported from mould table
support frame and is water-cooled. This mould support frame also
locates and supports the top-zone. This is an important of machine as it
ensures correct relationship between mould, top-zone and strand guides.
The pivot arms carrying the mould are oscillated to improve surface
finish of slabs by means of oscillation.
As the slab emerges from mould, it is cooled by a mist-spray cooling
system. The cooling strand is guided down by various roller segments
following the caster radius along a curved path. The upper sections of
segments can be raised hydraulically and are held by means of hydraulic
cylinders against packers, which are pre-set to give required slab
thickness. Immediately following the strand guide segments is the
straightener segment. This segment is designed to continuously remove
the curvature of the strand as it passes through the segment.
From the straightener, slab passes into withdrawal unit which has 7
segments arranged horizontally to support the slab as it progresses
towards cut-off machine. As strand emerges from cast withdrawal rollers,
the dummy bar disconnect mechanism is activated. The slabs are cut
into lengths by oxygen/gas machine which is supported on rails. As the
predetermined length is sensed, the machine lowers on to the slabs and
travels with the slabs at casting speed. The twin burners mounted on
cross carriages, cut the slab from either end. The discharge roller table
then transports the slabs to the cross transfer area. The slabs are
marked online by an Al-spray marking machine on their way to the cross
transfer.
Some Benefits:
-low carbon steel
strains
d oscillation parameters by using VAI DYNAFLEX
hydraulic oscillation system.
23. 23 | P a g e
Continuous Casting
Continuous Casting is the process whereby molten steel is solidified into
a "semi-finished" billet, bloom, or slab for subsequent rolling in the
finishing mills. Prior to the introduction of Continuous Casting in the
1950s, steel was poured into stationary mould to form "ingots". Since
then, "continuous casting" has evolved to achieve improved yield, quality,
productivity and cost efficiency. It allows lower-cost production of metal
sections with better quality, due to the inherently lower costs of
continuous, standardized production of a product, as well as providing
increased control over the process through automation. Steel is the metal
with the largest tonnage cast by this process, although aluminium and
copper are also continuously cast.
In Continuous Casting molten metal is tapped into the ladle from
furnaces. After undergoing any ladle treatments, such as alloying and
degassing, the ladle is transported to the top of the casting machine.
Usually, the ladle sits in a slot on a rotating turret at the casting
machine; one ladle is 'on cast' while the other is made ready, and is
switched to the casting position once the first ladle is empty.
From the ladle, the hot metal is transferred via a refractory shroud to a
holding bath called a Tundish. The Tundish allows a reservoir of metal to
feed the casting machine while ladles are switched, thus acting as a feed
metal feed to the mould and cleaning the metal buffer of hot metal as
metal is drained from the Tundish through another shroud into the top
of an open-base copper mould. The depth of the mould can range from
0.5 m to 2 m, depending on the casting speed and section size. The
mould is water-cooled and oscillates vertically to prevent the metal
sticking to the mould walls. A lubricant can also be added to the metal in
the mould to prevent sticking, and to trap any slag particles — including
oxide particles or scale — that may still be present in the metal and bring
them to the top of the pool to form a floating layer of slag. Often, the
shroud is set so the hot metal exits it below surface of the slag layer in
the mould and is thus called a submerged entry nozzle (SEN). In the
mould, a thin shell of metal next to the mould walls solidifies before the
metal section, now called a strand, exits the base of the mould into a
spray-chamber; the bulk of metal within the walls of the strand is still
molten. The strand is immediately supported by closely-spaced, water
24. 24 | P a g e
cooled rollers; these act to support the walls of the strand against the
Ferro static pressure of the still-solidifying liquid within the strand. To
increase the rate of solidification, the strand is also sprayed with large
amounts of water as it passes through the spray-chamber. Final
solidification of the strand may take place after the strand has exited the
spray-chamber.
Important Components of Continuous Casting:
: Steel from the electric or basic oxygen furnace is tapped into a
ladle and taken to the continuous casting machine. The ladle is raised
onto a turret that rotates the ladle into the casting position above the
Tundish. Liquid steel flows out of the ladle into the Tundish. Ladle slide
gate valves are used for greater pouring accuracy, increased ladle hold
time, and safer and easier ladle preparation.
: The shape of the Tundish is typically rectangular, but delta
and "T" shapes are also common. Nozzles are located along its bottom to
distribute liquid steel to the moulds.
The Tundish also serves several other key functions:
Enhances oxide inclusion separation
Provides a continuous flow of liquid steel to the mould during ladle
Exchanges
Maintains a steady metal height above the nozzles to the moulds,
thereby keeping steel flow constant and hence casting speed constant
as well.
Provides more stable stream patterns to the mould.
25. 25 | P a g e
Ladle shrouds are used for stream protection and reduction of steel re-
oxidation between ladle and Tundish.
: From the Tundish the molten metal enters
the mould through a shroud. Often, the shroud is set so the hot metal
exits it below surface of the slag layer in the mould and is thus called a
submerged entry nozzle (SEN).Submerged Entry Nozzles are used in the
26. 26 | P a g e
steelmaking process to prevent re-oxidation of the molten steel directly
from stream contact with the surrounding environment and from air
entrainment and splashing when the molten stream strikes the liquid
surface in the mould. Elimination of accretion formation and the
associated clogging of SENs will lead to increased strand speed, greater
time between changes of SENs, and reduced strand termination
incidence.
: The main function of the mould is to establish a solid shell
sufficient in strength to contain its liquid core upon entry into the
secondary spray cooling zone. Key product elements are shape, shell
thickness, uniform shell temperature distribution, defect-free internal
and surface quality with minimal porosity, and few non-metallic
inclusions. The mould is basically an open-ended box structure,
containing a water-cooled inner lining fabricated from a high purity
copper alloy. Mould water transfers heat from the solidifying shell. The
working surface of the copper face is often plated with chromium or
nickel to provide a harder working surface, and to avoid copper pickup
on the surface of the cast strand, which can facilitate surface cracks on
the product.
Mould oscillation is necessary to minimize friction and sticking of the
solidifying shell, and avoid shell tearing, and liquid steel breakouts,
which can wreak havoc on equipment and machine downtime due to
clean up and repairs. Friction between the shell and mould is reduced
through the use of mould lubricants such as oils or powdered fluxes.
Oscillation is achieved either hydraulically or via motor-driven cams or
levers which support and reciprocate (or oscillate) the mould.
: Segments are the set of rollers which helps the semi
solidified slabs to move from the mould to the torch cutting machine
through the guide rollers. Generally the rollers of the segments are in
taper form so that compression of the slab up to 3 meters is possible.
: Torch cutting machine is used to cut the
solidified slabs into desired length according to the demand. The torch
cutting machine in Tata Steel is supplied by GEGA.
27. 27 | P a g e
Commissioning Milestone of LD2 & Slab Caster
Equipment Month Year
Slab Caster 1 October 1993
Ladle Furnace 1 October 1993
Slab Caster 2 July 1994
LD Convertor 1 and GCP October 1994
LD Convertor 2 and GCP December 1994
DS Plant 1 June 1995
RH Degasser September 1996
Gas Recovery Of Convertor no. 1 March 1996
Gas Recovery Of Convertor no. 2 March 1996
Slab Caster 3 July 1998
DS Plant 2 August 1998
LD Convertor 3 October 1998
Ladle Furnace 2 February 1999
Slab Yard Management System April 1999
Gas Recovery Of Convertor no. 3 July 1999
Up gradation of Caster 1 - 2005
Up gradation of Vessel 1,2,3 - 2006-2007
28. 28 | P a g e
Introduction
EMBR Mold: EMBR stands for Electro Magnetic Braking.
It is a special kind of a mold quite similar to the conventional mechanical
(gear) mold in terms of physical appearance but hugely different from it
in the working aspect. A mold is a hollow container used to give shape
to molten or hot liquid material when it cools and hardens.
ELECTROMAGNETIC STIRRING AND
ELECTRO – MAGNETIC BRAKE For
CONTINUOUS CASTING
In order to continuously cast high quality steels for demanding purposes
electromagnetic stirring are a must for billets and blooms. Stirring will
improve strand quality, reproducibility, yield, production flexibility and
productivity. For each application the optimum stirrer choice can be
29. 29 | P a g e
made taking into account the steel grades cast, the strand sizes,
reduction ratio, etc. Optimizing the molten steel flow pattern is equally
important for slab casting, and here the electromagnetic brake is a
successful alternative to stirrers. Minimills with thin slab casting have
quickly become real competition to the integrated mills and today very
few integrated mills or conventional slab casters are being built or
planned. One of the remaining issues for the integrated mills has been
the steel quality, especially in terms of cleanliness and mold powder
entrapments. However, this situation has changed with the introduction
of the ElectroMagnetic BRake (EMBR) for thin slab casters.
EMBR MOLD is used for thin slab as well as conventional slab casters.
It is a prerequisite when:-
Casting thin slabs with higher throughputs
Aiming at higher quality segment.
30. 30 | P a g e
it facilitates nearly complete elimination of mold powder entrapments as
a result of reduced flow speed and turbulence.
It greatly improves coil surface quality and operates at relatively higher
speed than conventional steel casters.
It reduces mold copper wear, especially at higher casting speeds.
It reduces meniscus swelling resulting in a more even mold powder layer.
It increases productivity, product quality and lower operating costs.
Reduced Mold Powder Entrapments-
Inclusions remain small and relatively harmless because of the Ca-
treatment of the steel. Because of this and the high casting speed
normally used for thin slabs, mold powder entrapments constitutes
the major source of detrimental non-metallic inclusions.
With EMBR, the lower meniscus flow speed and the turbulence results
in that mold powder entrapment will be nearly eliminated.
More than 90% of the non-metallic inclusions are eliminated.
Improved Core Quality-
Higher speed of casting means low quality. When using an optimized
EMBR, the quality level at higher throughputs is improved.
The quality becomes equal or better to the quality level to that for
significantly lower casting speeds without EMBR.
Reduced Meniscus Swelling-
The braking reduces the meniscus swelling close to the narrow mold
sides. The resulting flatter meniscus allows for a more even layer of
molten mold powder, thus improving lubrication and reducing the
risks of surface cracks.
EMBR increases mold lifetime-
EMBR lowers the mold level fluctuation. Temperature cycling and
thermal fatigue of the copper plates are dramatically reduced.
Twice as more mold lifetime from casters using EMBR.
Increases Steel Temperature at Meniscus-
Heat transfer from the middle of the mold to the solidification front is
reduced.
31. 31 | P a g e
Hot steel is not pushed down into the strand but kept up higher in the
mold, resulting in an increase of steel temperature at meniscus.
Components of EMBR Mold:-
Wide and narrow plates
Electromagnets
Primary cooling system
Lateral roll
Spreading system
Narrow plate cylinder
Secondary cooling system
Wide and narrow plates- EMBR mold consists of two narrow plates
and two wide plates arranged perpendicular to each other to create
a rectangular opening if seen from top.
32. 32 | P a g e
An EMBR mold. The left plate is the movable wide plate.
Wide plate
The distance between the wide plates implies the thickness of the
slab to be cast which is normally about 215 in
LD#2 Slab caster#1.
Narrow plates
33. 33 | P a g e
The distance between the narrow plates implies the width of the
slab.
The plates are coated with pure copper of thickness 40 mm on one
side which are further coated with nickel and cobalt for improving
the wear resistance of pure copper as pure copper is costly and
degrades every 450-600 heats (1 heat=160 tonnes). The thickness of
this nickel and cobalt coating increases from 0.5 mm at the top to 2
mm at the bottom of the plates.
The junction of the copper coating and the plates is connected to
thermocouples which indicates the temperature of that point in a
screen. Copper is an excellent conductor of heat and electricity,
hence the heat from the molten steel is transferred is transferred to
the thermocouple via the copper coating so that the temperature
and the flow of the molten steel could be monitored analytically.
The thermocouples are welded to their slots in the plates.
There are 4 rows and 11 columns in each of the wide plates while
the narrow plates have 4 rows and 2 columns each with a total of
104 thermocouples.
The narrow plates are kept inclined at an angle of 1.1-1.28 degrees
towards the lower portion so that the molten steel ,which goes on
solidifying and hence consequently decreasing in dimension upon
solidifying, does not just slip from in between the plates.
The movement of the narrow plates are very slow which is 0.8
m/min. Each narrow plate is connected to two servos, one at the
top and the other at the bottom, which facilitates its movement in or
out. In every round of command given to the servos the narrow
plates move by 12.5 mm. There are two methods of movement of the
narrow plates so that the molten steel which is solidifying remains
in a healthy position. These are:-
S type
H type,
Depending on the motion which is used to cause the movement.
The plates contain cut lines (as shown in the figure) to facilitate the
free circulation of water in the plates to keep the temperature
moderate and the plates cool as well as prevent the copper coating
from getting degraded.
34. 34 | P a g e
Electromagnets- When molten steel is poured into the mold there
is a lot of turbulence in it which greatly tend to hamper the
properties of the steel which is being casted. Hence to obtain higher
grade and better quality steel the EMBR mold has electromagnets
which greatly tend to nullify this turbulence by developing a high
current electromagnetic field.
The electromagnets are attached to the wide plates and are totally 4
in number.
The control room screenshot of the electromagnets and its cooling
system/mechanism
There are two sets of coil on each of the wide plate or strand (visible
in the figure). There are two strands, namely:
Strand 1 upper coil, and
Strand 1 lower coil.
Each of the strands now further has two coils as we discussed
above.
Strand 1 upper coil has:
Coil 11A
Coil 11B
35. 35 | P a g e
Strand 1 lower coil has:
Coil 12A
Coil 12B
Each of the coils is water cooled continuously to maintain and
regulate the temperature. The water used here is a special kind of
water called “de mineralized water”. The properties of this cooling
system are as follows:
Inlet temperature = 41 °C (according to data)
Outlet temperature = 56, 59, 56, 60 °C (data for 4 coils)
Pressure = 6 bar
Flow rate = 200 l/min
Conductivity = 0.1360-1.418 µs/cm
The EMBR electromagnet will trip under the following conditions:
When the inlet temperature is 48 °C or more than that, and
When the conductivity>2 µs/cm. (it has to be less than 2 at all
times).
The current and voltage required to produce the electromagnetic
field is 560 Ampere and 180 volts respectively.
Primary cooling system- Primary cooling system implies the
cooling of the plates. The wide and narrow plates bear an intense
amount of heat from the molten steel so the need to be cooled down.
This is also done to ensure the safety of the copper plates. The
water used in this system is soft water.
Soft water circulates in
Wide plate at 4000 Lpm.
Narrow plate at 550 Lpm
Lateral roll- These are the rolls attached to the bottom of the mold
just below the plates to direct the solidifying steel towards the
bender and from where it proceeds on to the segments. These are
three in number. The average casting speed is 10218 m/min.
Spreading system- It consists of 4 hydraulic cylinders. It is used
for increasing the thickness of the slabs as per requirement. One of
the wide plate is kept fixed while the other is movable to adjust the
thickness. These 4 cylinders are fixed at 4 corners of the fixed plate.
36. 36 | P a g e
One end of the cylinder is fixed at the fixed end where it is clamped
and declamped (ie. Cylinder movement off and on resp.). Upon
declamping a hydraulic oil of very high viscosity index (around 400)
is made to enter the cylinder at very high pressure. This applies
pressure on the piston and pushes it inwards and this piston
subsequently pushes the movable plate. The amount by which the
movable plate has to be moved depends on the amount of the
hydraulic oil made to enter the cylinder and is measured by a gauge
attached to it. When the appropriate thickness has been achieved
the cylinder is again clamped to make the movable plate static at
this new position.
Narrow plate cylinder- there are 4 hydraulic cylinders placed in
the mold for the movement of the narrow plates. Each narrow plate
is attached to two cylinders, at the top and at the bottom.
These cylinders are connected to the servo valve and position
transducer. These receive the data from the operator and move the
narrow plates very slowly at the rate of 0.8 m/min.
37. 37 | P a g e
As seen in the figure, the servo valve is located in the leftmost box.
Attached to it on its right is the cylinder. The servo facilitates the
cylinder movement which is connected to the the narrow plate with
the help of a thread strand.
The main difference between the EMBR mold and other molds is
that here in EMBR molds the narrow plate’s movement is due to the
valves whereas in the normal molds it is due to the arrangement of
gears.
Secondary cooling system- This refers to the cooling of the molten
steel to form a slab. The slab of steel that comes out of the mold is
molten from inside and solid from outside due to cooling. Since we
desire completely solid slab hence water is sprayed on to it from the
38. 38 | P a g e
moment the slab gets out of the mold till the very last segment
Secondary cooling system
The water used in this system is normal tap water and is sprayed on the
slab directly perpendicular it from a pipe whose ends are made flat in
order to make sure that they come out with force and cover the
maximum surface area.
If this is not present then the heat from the molten steel inside the
solidified shell will cause the shell to melt and ultimately leading to
breakout or bleeding.
39. 39 | P a g e
Problems
There are various problems in a steel caster. These are mentioned below
with their frequency of happening in the form of a graph:
Problem wise distribution of unplanned mold change
Mold changes in FY ’12 and FY ‘13
Above plot shows various problems during operation of mold in a
slab caster.
3 major problems with mold is Breakout, Ramming problem and
Slab Bulging which share almost 80% of total mold problems.
Breakout is out of scope as research work is in progress for this
problem but it sure can be brought under control. How? We will
see this further in this project.
My scope was to work for Corner Gap Elimination as it’s the
major cause for breakouts that take place in casters.
The biggest problem in a steel caster is that of breakout or bleeding.
Bleeding is a term used when the solid shell of the slab ruptures and
the molten metal flows out. This condition will keep out the caster
from running for a considerable amount of time.
40. 40 | P a g e
When bleeding occurs all the steel that is in the mold flows out.
Steel from the tundish and ladle also drains which amounts to the
spillage of more than 200 tonnes of steel.
The segments also get damaged upon coming in contact with the
molten steel, thus creating more problems in terms of maintenance,
safety, reinstallation, etc.
A major hazard could be sensed when the molten metal flows and
occupies positions in the lower areas and solidify there.
Metal removal is yet another challenge that has to be faced.
In steel industry, ideally the caster is expected to be in the running
condition all the time, never stopping even for a minute until the
shutdown of the caster. Even if the caster stops for a minute it will be
termed as a loss because some amount of steel would have been casted
during that time. So when bleeding or breakout occurs one can very well
imagine the loss that the company faces.
Breakout/bleeding occurs due to the following reasons:
Corner gap developed between the narrow and wide plates
Coating problem/level fluctuations
Improper calibration at various points
Taper loss due to less or excessive angle of taper.
43. 43 | P a g e
Data table 2
On analyzing the above data one can easily suggest that corner gap is
to be held accountable for more than half of the times when breakouts
have occurred.
Hence if corner gap issue is brought under control then productivity as
well as income will increase and the amount of loss would go down to
a huge extent.
Corner gap problem: Corner gap is the gap that is developed
between the two adjacent narrow and wide plates upon continuous
casting. Corner gap is essential in molds. It is so because the width
arrangement for the slabs is done by the movement of narrow plates
under the influence of the servo. Now if the adjacent narrow and wide
plates are in contact with each other giving zero corner gap then the
narrow plate, upon movement, would graze the copper coating of the
wide plates which is undesirable. Hence some amount of corner gap
44. 44 | P a g e
must be present in the mold but it must not increase so as to create
problems.
Ideally corner gap should be 0.6 mm at the top and 0.9 mm at the
bottom. At the bottom more corner gap is needed because of the
increasing thickness of nickel and cobalt coating as well as considering
the shrinkage of the slab upon its movement downward.
Corner gap
It was observed however that once the mold was put into position, in
caster, corner gap abnormally increased to more than 1 mm, thereby
causing breakouts.
The following fishbone diagram will explain the vaious factors responsible
for a high corner gap. This diagram considers almost every factor
responsible for its cause because in order to remove a problem every
thing must be taken care of.
47. 47 | P a g e
Solution #1: Stopper modification
Since corner gap was a major issue it was tried to get under control by
adding an external stopnness over and above the four clamping bolts to
check the distance by which the loose plate can move. But it proved to
be ineffective. Increased Corner gap was tried to eliminate using stopper
in three ways:
PDCA 1:
PDCA 1: flexible due to cantilever design support
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Drawback : Not able to stop due to deflection.
PDCA 2:
PDCA 2: shims between two rigid stoppers
Drawback : able to stop but difficult to set 0.4 mm.
Wedge type stoppers with locking facility
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Solution #2: Mold and bender alignment
On the failure of stopper arrangements to control the increase in corner
gap, an alternate and reliable solution was needed.
The force required to compress high tensile Sa3O4 grade steel by 0.8 mm
was calculated. This force was too big for any usual explanation.
After that another aspect was looked upon- alignment of mold and
bender. Upon observation it was found that the foot rolls and the bender
rolls were not aligned properly.
ACTUAL REASON FOR THE OCCURRENCE OF CORNER GAP-
Due to ferrostatic force or misalignment forces, all looseness in entire tie
rod assembly and elongation of rod was responsible for loose plate to be
pushed back and create the gap.
Result
Hence the root cause of the problem was found out and appropriate
measures were adopted to avoid it. The frequency of breakout was greatly
reduced which is implied from the following data:-
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Total number down
The level difference of dark blue bar and the light blue bar indicates the
progress.
Thank You