STEEL PRODUCTION AT

COMPACT STRIP

PELLET MILL

Submitted by:-

SAROSH.RAHIL.RAHIM

CLASS:-ME-D

ROLL NO:-110106245

ENROLLMENT NO:-11SETME463

CONTENTS

• CHAPTER-1: INRODUCTION TO ESSAR GROUP

• CHAPTER-2: ESSAR STEEL PRODUCTS

• CHAPTER-3: WHAT IS STEEL AND IT’S USE

• CHAPTER-4: COMPACT STRIP PRODUCTION (CSP) MILL

• CHAPTER-5: HYDRAULIC SYSTEM FOR CSP MILL

CHAPTER-1: INTRODUCTION TO ESSAR

GROUP

ESSAR began as a construction company in 1969 and has

diversified into manufacturing, services and retail over the years

since then. Over the last decade, it has grown through strategic

global acquisitions and partnerships , capturing new markets and

discovering new raw material sources.

Today, ESSAR continues to expand its global footprint, focusing on

markets in Asia, Africa, Europe, the Americas and Australia. Essar

invests significantly in the latest technology to drive forward and

backward integration in its businesses, and on leveraging synergies

between these businesses. It also focuses on in-house research and

innovation to be a low-cost manufacturer with high-quality products

and innovative customer offerings.

ESSAR’S AREA OF BUSINESS INCLUDE:-

• STEEL ESSAR Steel is a global producer of steel with a footprint covering

India, Canada, USA, and Asia. It is a fully integrated flat carbon steel

manufacturer—from iron core to ready-to-market products. ESSAR

Steel has a current capacity of 9 million tons per annum (MTPA).

With its aggressive expansion plans in India as well as Asia and

America, its capacity will go up to 20 to 25 MTPA. Its products find

wide acceptance in highly discerning consumer sectors, such as

automotive, white goods, construction, engineering and shipbuilding.

ESSAR Steel produces world-class steel at HAZIRA. It is India’s

largest exporter of flat Products mainly to US, Europe, South East &

Middle East.

• ENERGY

ESSAR energy is a world-class, low-cost, integrated energy company

focused on India and positioned to capitalize on India's rapidly growing

energy demand. We have an established track-record and assets worth

US$12 billion across the power and oil and gas industries. The combined

assets of Essar Power and Essar Oil constitute Essar Energy.

• INFRASTUCTUREESSAR has a strong foundation in infrastructure projects, with proven

capability in managing ports and handling large, complex engineering,

procurement and construction projects.

• SERVICES

ESSAR offers a wide portfolio of services that cater to diverse

sectors that include shipping, business process outsourcing,

telecom and realty.

CHAPTER 2:- ESSAR STEEL PRODUCTS

1). IRON ORE PELLETS

Iron Ore Pellets are spheres of typically 8–18 mm (0.31–0.71 in) to

be used as raw material for blast furnaces. They typically contain

67%-72% Fe and various additional material adjusting the chemical

composition and the metallurgic properties of the pellets.

2).HOT BRIQUETTED IRON (HBI)

Hot Briquetted Iron (HBI) is a form of iron that has been compacted

at a temperature greater than 650° C at time of compaction and has

a density greater than 5000 kilograms per cubic meter (5000 kg/m3).

3). COLD ROLLED PRODUCT

Hot rolled steel that has been rolled to its specified final thickness at

room temperature is known as cold rolled product.

4). GALVANIZED PRODUCT

The process of applying a protective zinc coating to steel or iron

products to prevent rusting is known as galvanized product.

5).CHEQUERED PLATES

Patterned or perforated metal plate used to make non-slip flooring in

mineral preparation plants, power stations etc.

CHAPTER 3:- WHAT IS STEEL AND IT’S

USE IN EVERYDAY LIFE

Steel is an alloy of iron and carbon, that is used in

construction of roads, railways, appliances, buildings and

various other applications because of it’s hardness and

tensile strength.

• Iron is the main ingredient in various forms of iron and

steel, but the various types of metals contain other

elements as well. Sometimes these elements are

unwanted; other times they're intentionally added.

• The various elements used in steel are :- Carbon,

Manganese, Phosphorous, Sulfur, Silicon, Nickel,

Chromium,

Elements of Steel Composition :-

1). Cast Iron:-

Cast iron contains high levels of carbon, which makes it

a hard, brittle metal. Cast iron was commonly used

throughout Europe to make church bells and, in colonial

America, pots and pans.

2).Wrought Iron:-

Wrought iron is a strong, durable metal with a low

carbon content. Items such as locks, bolts, tools, and

fences are crafted out of this metal.

3).Plain Steel:-

During the early 20th century, new processes in steel

production allowed steel to surpass iron as the most

widely used structural metal. Its great strength and

affordability allowed craftsmen to construct sturdier

bridges and higher buildings.

4). High Strength Steel:-

Adding alloys to steel increases strength and it

becomes wear-resistant metal, which can be used for

various purposes.

PROCESS FLOW

The raw materials like Iron , Carbon , Manganese ,

Phosphorous , Sulfur , Nickel , are obtained and are

transported to the Vizag Pellet Plant .

In the Vizag Pellet Plant these raw materials are mixed

together, and converted in the form of iron ore pellets ,

which is done by the moulds in the pellet machine . This

is done because transportation of the material is easier

in this form .

These pellets are then shipped to the Hazira Facility

where they are used as raw materials for the blast

furnace, and the iron making and steel making process

can be started. These pellets are usually 8-18mm in size.

CHAPTER 4:MANUFACTURING PROCESS

IN COMPACT STRIP PELLET MILL

Iron Making :-

Iron ore, limestone and coke is the ‘’stock’ of the blast

furnace. This is fed into the furnace at its top. A variety of

processes take place within the blast furnace, as the

‘stock’ slowly moves downwards and temperatures

increase .

The removal of oxygen through the chemical process

called ‘reduction’ is crucial (oxygen combines with

carbon monoxide, forming carbon dioxide gas). As the

stock travels down the furnace, various impurities and

gases are removed until only molten iron and slag are

left.

Steel Making :-

It is done to remove slag or impurities after the iron

making process.

Electric Arc Furnace steelmaking is the manufacture of

steel from scrap melted by electric arcs. In an electric

arc furnace, a batch of steel ("heat") may be started by

loading scrap into the furnace, sometimes with a "hot

heel" (molten steel from a previous heat). Gas burners

may be used to assist with the melt down of the scrap

pile in the furnace. As in basic oxygen steelmaking,

fluxes are also added to protect the lining of the vessel

and help improve the removal of impurities. Electric arc

furnace steelmaking typically uses furnaces of capacity

around 100 tonnes that produce steel every 40 to 50

minutes for further processing.

• Slab is cut to the predecided length and this hot slab is directly fed

to the tunnel furnace (of length 185-260m). In tunnel furnace slab

temp is equalized across the cross-section. Temp of slab at entry of

tunnel furnace is about 950°C and it is heated to a temp of about

1050°C. Hot slab from tunnel furnace is passed through high

pressure descaler and then directly to mill for making hot rolled coil.

• CSP Mill is equipped with automatic gauge control (AGC),

Hydraulic loopers for F1-F4,differential tension looper for F5,

Continuously Variable Crown, Work roll bending and shifting to get

good quality of strip profile and flatness.After F6 strip passes

through automatically controlled laminar cooling for getting good

mechanical properties. This strip is coiled and transported to coil

yard by pallet type conveyor.

• CSP has got many advantages over conventional as

mentioned:

• About 50%of space is required as compared to conventional Hot

Strip Mill of same size.

• Overall energy consumption for production of Hot Rolled coils is only

90,000 k cal / ton with cold charged EAF.

• 29-30 minutes process time is required as against 8 hours for the

conventional thick slab casting process from slab to coil.

• Since no slab reheating or roughing reduction is involved, the rolling

mill cost index is just 100 compared to 150 for the conventional thick

slab rolling process.

• Very high labour productivity.

• It enables to produce strips of thickness less than 1mm.

CHAPTER 5:-HYDRAULIC SYSTEM

• Hydraulics can be defined as the transmission and

control of forces and movements by means of fluids.

• Salient features of hydraulics:-

1). High forces(torques)within a small space

2).Automatic load matching

3).Start of movement under full load

4).Simple step less control of speed , torque or force.

5).Simple overload protection.

• An Automatic Lubrication System (ALS), often referred to

as a Centralized Lubrication System, generally

comprises a controller or timer, a pump and reservoir,

metering valves and fittings and supply and feed lines. It

typically delivers a controlled amount of lubricant (either

grease or oil) to multiple, specific locations on a machine

while the machine is operating, at specific times from a

central location for an Automatic Lubrication System.

REASON FOR AUTOMATIC

LUBRICATION SYSTEM

Whether the equipment is stationary, such as in a

manufacturing facility or mobile such as trucks, mining or

construction equipment, applying lubricant is often most

effective when it is dispensed in small, measured

amounts over short, frequent time intervals. However,

time and human resource constraints or sometimes the

physical location or type of machine often makes this

approach to lubrication impossible. As a result,

production cycles, machine availability, and manpower

availability dictate the intervals at which machinery is

lubricated which is not optimal for the point requiring

lubrication. Auto lube systems are installed on machinery

to address this problem.

BENEFITS OF AUTOMATIC LUBRICATION

SYSTEM

• Auto lube systems have many advantages over traditional methods

of manual lubrication:

• All critical components are lubricated, regardless of location or ease

of access

• Lubrication occurs while the machinery is in operation causing the

lubricant to be equally distributed within the bearing and increasing

the machine’s availability.

• Proper lubrication of critical components ensures safe operation of

the machinery.

• Less wear on the components means extended component life,

fewer breakdowns, reduced downtime, reduced replacement costs

and reduced maintenance costs

• Measured lubrication amounts means no wasted lubricant

Safety - no climbing around machinery or inaccessible areas (gases,

exhaust, confined spaces, etc.)

DIFFERENT TYPES OF LUBRICATION

SYSTEM

• There are several different types of automatic lubrication

systems including:

• Single Line Parallel systems

• Dual Line Parallel systems

• Single Point Automatics

• Single Line Progressive systems (or Series

Progressive)

• Single Line Resistance

• Oil Mist and Air-Oil systems

• Oil re-circulating

• Chain lube systems

• Single Line Parallel:-

• The first single-line parallel system for industry was introduced in

1937 by Lincoln Engineering (now known as Lincoln Industrial) in

the U.S.A.

A single line parallel system can service a single machine, different

zones on a single machine or even several separate machines and

is ideal when the volume of lubricant varies for each point. In this

type of system, a central pump station automatically delivers

lubricant through a single supply line to multiple branches of

injectors. Each injector serves a single lubrication point, operates

independently and may be individually adjusted to deliver the

desired amount of lubricant.

• Dual Line Parallel:-

• A dual line parallel system is similar to the single line parallel system

in that it uses hydraulic pressure to cycle adjustable valves to

dispense measured shots of lubricant. It has 2 main supply lines

which are alternatively used as pressure / vent lines. The advantage

of a two-line system is that it can handle hundreds of lubrication

points from a single pump station over several thousand feet using

significantly smaller tubing or pipe.

• Single Line Progressive

• A single line progressive system uses lubricant flow to cycle

individual metering valves and valve assemblies. The valves consist

of dispensing pistons moving back and forth in a specific bore. Each

piston depends on flow from the previous piston to shift and displace

lubricant. If one piston doesn’t shift, none of the following pistons will

shift. Valve output is not adjustable.

• GREASE:-

• Grease is a semisolid lubricant. It generally consists of a soap

emulsified with mineral or vegetable oil.[1] The characteristic feature

of greases is that they possess a high initial viscosity, which upon

the application of shear, drops to give the effect of an oil-lubricated

bearing of approximately the same viscosity as the base oil used in

the grease. This change in viscosity is called thixotropy. Grease is

sometimes used to describe lubricating materials that are simply soft

solids or high viscosity liquids, but these materials do not exhibit the

shear-thinning (thixotropic) properties characteristic of the classical

grease. For example, petroleum jellies such as Vaseline are not

generally classified as greases.

• Greases are applied to mechanisms that can only be

lubricated infrequently and where a lubricating oil would

not stay in position. They also act as sealants to prevent

ingress of water and incompressible materials. Grease-

lubricated bearings have greater frictional characteristics

due to their high viscosity.

• NLGI(National Lubricating Grease Institute)

SERVO (IOCL- Indian Oil Corporation Limited)

• MAK100(BPCL- Bharat Petroleum Corporation Limited)

Dual Line Grease Lubrication

• Dual Line Grease Lubrication systems are commonly used for

effective and economical metering of grease and high viscosity oils

for the lubrication of individual machines and composite groups with

upto 1000 lubrication points. Ideally suited where points span long

distances, have high lubrication entry resistance or where sections

require individual and automatic lubricant control.

• A typical Dual Line System comprises of a High Pressure Pump,

Change over Valve, Dual Line Metering devices, Tubing, fittings,

End-Of-Line Pressure Switch Assembly and Electrical Control

Panel. The modular design and the wide range of Lincoln Products

enable optimum designing of the lubrication systems best suited to

the customer’s requirement.

The salient features of the Dual Line System are as follows:

• Monitoring of system ensuring lubrication of all points with the

desired quantity and frequency.

• Monitoring of individual (critical) points as optional.

• Modular design enables economical and optimum system design.

• High Pressure system design to ensure Quality of Lubricant at high

operating temperatures, Reduced initial fill & residual grease in the

system, Faster & shorter cycles resulting in better lubrication and

capability of handling high bearing back pressure & expansion

possibilities.

THANK YOU