PHILOSOPHY OF SETTING UP VARIOUS ROLLING MILLS ENGINEERED BY KORUS IN PAST 9 YEARS

Transcription

1 PHILOSOPHY OF SETTING UP VARIOUS ROLLING MILLS ENGINEERED BY KORUS IN PAST 9 YEARS D.D. Kapur Rajesh Popli Randhir Rana Korus Engineering Solutions Pvt. Ltd.

2 Korus Engineering Solutions Pvt. Ltd. Set up in the beginning of year 2005 to serve the Steel Industry in the field of Technical Consultancy and Project Design & Engineering Services. The Company has been fortunate to be associated with several interesting projects set-up by reputed groups namely Jindals, Usha Martin, Bhushan Power & Steel, Kalyani Steels, MUSCO, Vardhman, Adhunik Steels, L&T, Aarti Steels, Jayaswal Neco, Sunflag, BMM Ispat, Mittal Corporation and many more. During this period, India s Steel production has increased from 50 MTPA to 80 MTPA i.e. by 30 MTPA. Korus has played a significant role in the course of this development.

3 Projects Spectrum Embraced 42 Nos. Rolling Mills producing diverse products with a total output of about 15 MTPA. Capacity of individual mills, ranging from 100,000 TPA to 1.4 MTPA. 12 Nos. Steel Melt Shop in capacities ranging from 100,000 to 2 MTPA with a total capacity of about 11 MTPA using both Electric Arc Furnaces and Induction Furnaces. 2 Pellet Plants of capacity 4.5 MTPA & 1.2 MTPA respectively. 4.5 MTPA Iron Ore Beneficiation Plant. 500 TPD DRI Plant and 300 TPD Lime Kiln Project. 3 Cut-To-Length Lines for Coil Plates 1 Beam Welding Plant 1 Plate Heat Treatment Line

4 CAPACITY Total No. of 42 Rolling Mills Engineered by Korus 15 TMT Rebar Mills 7.1MTPA 11 Alloy Steel Bar Mills 2.26MTPA 3 Wire Rod Mills 1.45 MTPA 4 Bar cum Wire rod Mills 0.975MTPA 6 Heavy bar Mills 2.15MTPA 3 Structural Mills 1.7MTPA 1 Plate Mills 0.8MTPA TMT Rebar Mills 7.1MTPA Alloy Steel Bar Mills 2.26MTPA Wire Rod Mills 1.45 MTPA Bar cum Wire rod Mills 0.975MTPA Heavy bar Mills 2.15MTPA Structural Mills 1.7MTPA Plate Mills 0.8MTPA

5 Capacity Range of Rolling Mills Annual Capacity (Tons) TMT Bar Mills Alloy Steel Bar Mills Wire Rod Mills Bar cum Wire Rod Mills Heavy Bar Mills Structural Mills Plate Mill Below 100, , , , , , , , , ,000-1,000, > 1,000, TOTAL

6 Emerging Trends of TMT Rebar Mills: Capacity - Minimum- 100,000 TPA Maximum- 1,400,000 TPA Maximum Rolling Speed Mills upto 150,000TPA = Mills upto 200,000TPA = to 700,000 TPA Mills 600,000 to 1.4 Mtpa = Billets Weight = m/s Multi Slit Rolling Upto 15 m/s Single Slit Combined With High Speed Rolling through No Twist Block upto 45 m/s upto 2500 kg in big mills Min. 360 kg in small mills

7 Emerging Trends of TMT Rebar Mills: Mill Configuration Mills upto 150,000TPA Single stand 3 hi Rougher + Continuous Mill Bigger Mills Fully Continuous Mill 200 TPH JSPL(PATRATU) & JSW(TORANGALLU )1.0 MTPA CAPACITY TMT BAR MILL(FIG-1.1

8 245 TPH JSPL(ANGUL) 1.4 MTPA CAPACITY TMT BAR MILL 220 TPH JSW(TORANGALLU) 1.2 MTPA CAPACITY TMT BAR MILL(FIG-1.3)

9 20 TPH BMA STAINLESS LTD. 100,000 TPA CAPACITY TMT BAR MILL (FIG-1.4 BMA STAINLES LTD. 100,000 TPA CAPACITY TMT BAR MILL SHRI BAJRANG METALLIC & POWER LTD. 150,000 TPA CAPACITY TMT BAR MILL

10 35 TPH UNIVERSAL ROLLING MILL WLL. 175,000 TPA TMT BAR MILL (FIG-1.6)

11 Emerging Trends of TMT Rebar Mills: End Product Type Straight Bars through Cooling bed 8 to 40mm Diameter (New sizes50mm & 63mm) Coils Through Wire Rod Block 6 to 12mm Diameter Spooler Coils 8 to 32mm Diameter (Future Mills)

12 Emerging Trends of TMT Rebar Mills: Bar Bundles: kg Sub Bundles & upto 2 ton Master Bundles Smaller Mills 2 4 ton x 12m long Straight Bundles All high Production Mills

13 Emerging Trends of TMT Rebar Mills: Yield Improvement through Following Measures: 1. Hot Charging 2. Direct Rolling 3. Use of Higher Billets Weight upto 2500kg 4. Use of Walking Beam Furnaces 5. Use of Minimum no. of Slits 6. Length Optimization on Cooling bed 7. Deposition of one bar in each notch of Cooling Bed Rake to achieve individual bar alignment at aligning rollers 8. Production of Rebars in Coils Modern High Production Mills are able to achieve yield as high as 98%

14 Alloy Steel Bar Rolling Mills S.NO. COMPANY CAPACITY (TPA) 1 Jayaswal Neco Industries Limited,Raipur (Chattisgarh) 100,000 2 Kalyani Gerdau Steel Limited, Tadipatri (Andhra Pradesh) 300,000 3 Kalyani Steel Limited, Hospet (Karnataka) 84,000 4 Kalyani Carpenter, Pune (Maharastra) 175,000 5 Sona Alloys Pvt. Ltd. Lonand (Maharastra) ** 250,000 6 Adhunik Metaliks Ltd. 250,000 7 Mahindra Ugine, Khopoli ( Maharastra) 200,000 8 Upper India Steel Manufacturing, Ludhiana (Punjab) 100,000 9 Vardhman Special Steels, Ludihana (Punjab) 150, Mittal Corporation,Pitampur, M.P. ** 150, Bhushan Power & Steel,Jharsuguda, Odisha ** 500,000

15 Salient features of Alloy Steel Bar Mills 1. Use of Walking Beam /Walking Hearth furnaces for uniform & gradual heating of billets /blooms with minimum scaling & decarburization. 2. High pressure Water Descaler at 260 bar working pressure. 3. Roughing Mills with three types of Configuration a ) Shiftable Reversing Rougher stand b) Single/Two Stand 3-Hi Mill c) 4 to 6 stands Continuous Mill in H/V Configuration with free run out 4. Intermediate & finishing mill in Continuous H/V Configuration 5. Use of Housingless Stands in the Mill to produce Bars in close tolerances. 6. Use of Reducing & Sizing Blocks to further achieve close tolerances 1/3 DIN to ¼ DIN & free size rolling. 7. Use of abrasive saws for dividing the bars to customer lengths free of end deformation & burs. 8. Use of Dimensional profile gauge to produce bars with close tolerances & have constant check during production.

16 TOP & BOTTOM FIRED PUSHER TYPE RE-HEATING FURNACE WALKING HEARTH TYPE RE-HEATING FURNACE

17 WALKING BEAM TYPE RE-HEATING FURNACE

18 SINGLE STAND 2 HI-SHIFTABLE HOUSINGLESS REVERSING MILL 3-HI ROUGHING MILL STAND CONTINUOUS ROUGHING MILL WITH FREE RUN OUT

19 FINISHING MILL CONFIGURATIONS FOR ALLOY STEEL BAR MILLS CONTINUOUS H-V MILL VARIABLE REDUCTION MILL 4/5 STAND KOCKS BLOCK

20 KOCKS TECHNOLOGY

21 ABRASIVE SAW FIXED & TRAVELLING HOT SAWS TURN OVER COOLING BED

22 WIRE ROD MILLS S.NO. COMPANY CAPACITY (TPA) 1 Bhushan Power & Steel Ltd. Jharasuguda (Odisha) * 500,000 2 Jindal Steel & Power Limited, Patratu ( Jharkhand) 600,000 3 JSW Steel, Torangallu ( Karnataka) 600,000 4 Jayaswal Neco Industries Limited, Raipur(Chattisgarh) 250,000 5 Shri Bajrang Metallic & Power Ltd., Raipur (Chattisgarh) * 150,000 6 SKS Ispat, Raipur (Chattisgarh) * 175,000 7 Mittal Corporation, Pithampur (M.P.) * 150,000

23 160 TPH 0.6 MTPA CAPACITY WIRE ROD MILL AT JSPL (PATRATU) & JSW (TORANGALLU) 110 TPH 0.5MTPA CAPACITY WIRE ROD-CUM-BAR MILL AT BHUSHAN STEEL & POWER LTD., JHARSUGUDA

24 30 TPH 1.5 LTPA CAPACITY WIRE ROD-CUM-BAR MILL AT MITTAL CORP. LTD., INDORE 50 TPH 2.5 LTPA CAPACITY WIRE ROD MILL AT JAYASWAL NECO INDUSTRIES PVT. LTD., RAIPUR

25 The Emerging Trends in Coil route are: 1. Almost all mills adopting V-Type Stand configuration as compared to earlier use of H/V Stands in many blocks with maximum rolling speed 110m/s. 2. Blocks with different reduction for rolling different grades: a) 16% reduction for a mix of Stainless Steels. b) 18% reduction for a mix of Stainless Steels & Alloy Steels. c) 20% for low, medium & high carbon steels and low alloy steels. 3. SMS MEER has come up with blocks having individually driven stands which can cater to different reduction ratios for rolling different grades of steel. The arrangement also allows great economy in T.C. Ring consumption as rings of any size could be used in any stand as compared to requirement of sets with matched ring diameters. Due to reduced mechanical equipment in the drive, efficiency is high and maintenance requirement low. 4. Use of Ring Distributor and easy-down system at reformer station. Coil Handling by Pallet/C-hook conveyors,horizontal compacting & Binding machines. Vertical compactors are expected to become popular in future. 5. Garret Coilers of special design with spiral pre-forming of the coil especially for rolling of coils in large weights of 2-3 t and at high rolling speeds. 6. Use of Reducing & Sizing Mill in WRB Line to produce Wire Rods in 0.5 mm increments and in closer tolerances

26 KOCKS BLOCK WIRE ROD BLOCK GROUP DRIVEN STANDS WIRE ROD BLOCK INDIVIDUALLY DRIVENSTANDS

27 PALLET CONVEYORS POWER & FREE C-HOOK CONVEYORS HORIZONTAL COIL COMPACTOR COMPACTED & BOUND COILS AT DISCHARGING STATION

28 HEAVY BAR MILLS S.NO. COMPANY CAPACITY (TPA) 1 JSW steel, Salem (Tamil Nadu) 400,000 2 Kalyani Steel Limited, Hospet (Karnataka) 250,000 3 Sunflag Iron & Steel co., Bhandara (Maharastra) 200,000 4 Usha Martin Ltd., Jamshedpur 250,000 5 Bhushan Power & Steel Ltd. Jharasuguda (Odisha) * 550,000 6 Jayaswal Neco Industries Limited, Raipur (Chattisgarh) * 500,000

29 Heavy Bar Mills generally comprise: 1. Walking Beam Furnaces for heating of blooms or in some case a top & bottom fired pusher furnace. 2. High pressure Water Descaler at 260 bar working pressure. 3. A Reversing Blooming Mill served by Manipulators on both sides, Tilting Fingers on one side or preferably both sides, Grip Tilter on entry or both sides. All mills have hydraulic balancing of top rolls and have automatic screw down for roll positioning in each pass. 4. A Hot Saw with Gauge after Reversing Mill. 5. A Turn-over Cooling Bed for products finished in Blooming Mill to 8 Stand H/V Continuous Finishing Mill. 7. Fixed & Travelling Hot Saws for dividing the rolled bars into customer s lengths. 8. Turn-over Cooling Beds. 9. Bar Handling System with Bundling & Tying Facilities.

30 100 TPH 0.5 MTPA HEAVY BAR MILL AT JSW, SALEM 50 TPH 0.25 MTPA HEAVY BAR MILL AT USHA MARTIN, JAMSHEDPUR

31 0.2 MTPA HEAVY BAR MILL AT MUSCO, KHOPOLI 40 TPH

32 2 HI-REVERSING MILL CONTINUOUS H-V MILL HOT SAW WITH LENGTH MEASURING GUAGE TURN OVER COOLING BED

33 STRUCTURAL MILLS S.NO. COMPANY CAPACITY(TPA) 1 Jindal Steel & Power Ltd,(MLSM) Raigarh (Chattisgarh) 600,000 2 Jindal Steel & Power Ltd, (RUBM) Raigarh (Chattisgarh) 600,000 3 Jayaswal Neco Industries, Raipur, Chattisgarh (India) * 500,000

34 THESE STRUCTURAL MILLS COMPRISE: Equipment JSPL JNIL RUBM MLSM HBSM Reheating Furnace 160 TPH Walking Beam 200 TPH Walking Beam 90 TPH Walking Beam Roughing Mill 2-High Reversing Ø 1250 x 2500 mm driven by 2x4250 kw D.C. Motors 5-Stand Continuous Mill in H-V-H-H-V Configuration with free run-out 2-High Reversing Mill Ø 950x2300 mm driven by 2x2200 kw D.C. Motors. Intermediate Mill 1-Stand Reversing, 2-High 900x1800 mm driven by a 5850 kw DC Motor Finishing Mill 3-Stand Tandem Mill with hydraulic gauge control 10 Stand Mill with individually driven Housingless Stands, 8 Stand Mill with individually driven Housingless Stands Hot Cutting Facilities 2-Hot Saws Dividing Flying Shear -- Cooling Bed Walking Beam Type 120 m long Rake Type Rake Type 90 m long 90 m long Straightener Multi Roller Multi Roller Multi Roller Cold Cutting Cold Saws with gauges Cold Saws with gauges Cold Saws with gauges Bar Stacking, Bundling, Binding etc. Provided Provided Provided

35 The Housingless Stands used in the Structural mills can be used in very flexible configurations viz; Universal Stands for rolling Beams and Channels 2-High Horizontal Stands 2-High Vertical Stands 2-High H/V Stands Different configurations are needed in the continuous mill to roll different sections. 8-Stand Mill for JNIL shall typically work as follows: H-V-H-V-H-V for rolling Rounds & RCS H-V-H-H-H-H-H for rolling Angles U-U-U-H-U-U-H-U for rolling Beams

36 150 TPH RAIL & UNIVERSAL BEAM MILL AT JSPL, RAIGARH 200 TPH 0.6 MTPA CAPACITY MEDIUM AND LIGHT STRUCTURAL MILL AT JSPL, RAIGARH

37 90 TPH 0.5 MTPA CAPACITY BAR & SECTION MILL AT JAYASWAL NECO INDUSTRIES PVT. LTD., RAIPUR

38 2-HI REVERSING MILL UNIVERSAL HOUSINGLESS STAND

39 2 HI HORIZONTAL/VERTICAL HOUSINGLESS STAND

40 HOUSINGLESS UNIVERSAL STAND HOUSINGLESS STAND IN 2-HI CONFIGURATION HOUSINGLESS UNIVERSAL STAND TANDEM MILL

41 MULTI ROLL STRAIGHTENER RAKE TYPE COOLING BED STACKS OF PILED BEAMS & ANGLES

42 Plate Mill S.NO. COMPANY CAPACITY (TPA) 1 Jindal Steel & Power Ltd, Raigarh (Chattisgarh) 800,000 JSPL s Plate Mill at Raigarh can produce discreet plates 6 to 100 mm thick in widths 1500 to 3000 mm and coil plates in 4-20 mm thickness in widths 1500 to 2600 mm depending on thickness

43 The Plate Mill Facilities Comprise: A 200 TPH Walking Beam Reheating Furnace A Hydraulic High Pressure Water Descaler A 900 mm Vertical Edging Stand Slab Turning Device on Roughing Mill Entry Side A 2-High 1350 x 3750 mm Reversing Roughing Mill driven by 2 x 2500 HP D.C. Motors at 0-30/70 rpm. A 4-High Ø 900 / Ø 1600 x 3750 mm Finishing Steckel Mill driven by 2 Nos HP D.c. 0-40/100 rpm An Up-Coiler with Pinch Roll Coil Handling System A Hot Plate Leveller A Dividing Shear Cooling Bed for mm Thick Plates A Cooling Bed for plate thickness 6 to 20 mm Side Shearing Rotary Shears A Dividing Shear with Gauge Plate Collecting Bed

44 About 60% production of products are in Coil Plates and the balance 40% in discreet plates. The Coil Plates are produced in weights upto 31 T. Cut-To-Length lines have been installed to convert coils to straight plates. About 20% coils are dispatched directly to customer for processing at their end. Two Normalizing Furnaces and a Cold Levelling facility is installed off-line to produce Normalized and levelled plates

45 200 TPH 0.8 MTPA PLATE MILL AT JSPL, RAIGARH SLAB DISCHARGE AT FURNACE

46 ROLLING IN 2-HI MILL (FIG-6.3) STACK OF COILS (FIG-6.4)

47 HOT CHARGING & DIRECT ROLLING Though hot charging of Slabs and Blooms / Billets had been successfully used in JSPL and JSW, there is a growing trend in the country to go for Direct Rolling. Bajrang Steels in Raipur can be considered the initiator of this trend who first started direct rolling of billets in their Bar Mill. The direct rolling is becoming possible due to the improvement in casting speed at the casters, optimization of secondary cooling, installation of insulation hoods and adopting high speed transport after cutting, to preserve heat in the billets and reduce temperature differential between surface and core. Though rolling of smaller length billets in 3-High Roughing Mills has been successfully achieved, rolling of billet greater than 3 to 4 m long necessitates the installation of an Induction heater to ensure a starting rolling temperature of ~1000 C and to achieve a more uniform temperature across the cross section of billet within 30 C.

48 The new mills are being planned for rolling rebar & structures with direct rolling. It is becoming feasible to roll 70-75% of billets directly % cold billets have to be rolled through Reheating Furnace. To reduce the percentage of cold billets, following measures are being adopted: Use of Shiftable stands for quick groove changing. Use of Quick Roll changing equipment in finishing section. Use of Combi-Rolls with Tungsten Carbide rings to increase pass life and reduce groove and roll changing intervals.

49 It is recommended to install stronger Roughing Mill equipment capable of accepting billets temperature of 950 C. The rolling load increases by 25 to 30% at 950 C as compared to a normal billet rolling temperature of 1150 C. In mills where attempts of direct rolling was made without such considerations, breakage of rolls, bearings and drive equipment have taken place, resulting in unplanned shut downs and consequently lower productivity.

50 DIRECT BILLET FROM CASTER ROLLING IN 3-HI ROUGHING MILL (WITHOUT RE-HEATING IN FURNACE)

51 LONG HOT BILLET FROM CASTER PASSING THROUGH INDUCTION HEATER FOR ROLLING IN CONTINUOUS MILL

52 Endless Casting and Rolling(ECR) This Emerging Rebar Rolling Trend for Small & Medium Sized Mills upto 300,000 TPA Capacity is being contemplated for some upcoming projects. This has been encouraged by the successful working of Danieli micro- mill at CMC Steel, Arizona, U.S.A. It is the most cost efficient solution for production of Rebars.Endless Rolling of 8500m long 130mm sq. billet has already been achieved for 23 hours per day with only one hour change over time on regular basis.

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