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Industrial training/Bhushan Power and Steel

1 DhruvDuggal/1021030064

COMPANY PROFILE

“Our mission is to grow our company by providing innovative strong and

high performance products and solutions to meet our global customer

needs.” Bhushan Steel Ltd formerly known as Bhushan Steel & Strips Ltd. is a

globally renowned one of the leading prominent player in Steel Industry.Backed

by more than two decades, of experience in Steel making, Bhushan Steel is now

India’s 3rd largest Secondary Steel Producer company with an existing steel

production capacity of 2 million tones per annum’s (approx.). It was the vision

of the founder; Brij Bhushan Singal, that the first stake was driven into the soil

of Sahibabad (Uttar Pradesh) in 1987. His vision helped BSL overcome several

periods of adversity and strive to improve against all odds. The company has

three manufacturing units in the state of Uttar Pradesh (Sahibabad Unit),

Maharashtra (Khopoli unit), and Orissa Plant (Meramandali unit) in India and

sales network is across many countries. The company is a source for vivid

variety of products such as Cold Rolled Closed Annealed, Galvanized Coil andSheet, High Tensile Steel Strapping, Colour Coated Coils , Galume Sheets and

Coils, Hardened & Tempered Steel Strips , Billets, Sponge Iron, Precision

Tubes and Wire Rod. As one of the prime movers of the technological

revolutions in Indian Cold Rolled Steel Industry, BSL has emerged as the

country’s largest and the only Cold Rolled Steel Plant with an independent line

for manufacturing Cold Rolled Coil and Sheet up to a width of 1700mm, as wellas Galvanized Coil and Sheet up to a width of 1350 mm.

In due course of time, BSL has grown incredibly its turnover and production

capacity by successive expansions as well as improved realizations with these

manufacturing units.

The dynamic reason of awesome and unparallel growth of BSL, is rapidintegration on the Steel value chain; conceivably, it would be its unwavering

http://bhushan-group.org/sahibabad.asp


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http://bhushan-group.org/wirerod.asp


















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focus on acquiring the latest technology and know how, also the BSL’s

commitment to provide its customers with the best quality products.

Given a vibrant Steel industry dynamics in India, we are on a course to becomea fully Integrated Steel & Power Company with market leading offerings in

value added Steel in Automotive and White Good Segment with the quality

been approved by ISO 9001:2008 & ISO 14001:2004.

FIGURE1.1- GROWTH TRAJECTORY

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FIGURE1.2-MOVING UP THE VALUE CHAIN

Bhushan Power & Steel Limited, a fully integrated 2.3 Million TPA

Steel making Company with turnover of INR 5020 Crores (USD 1123

Million) and 7 World Class ISO 9000 Certified State of the Art Plants at

Chandigarh, Derabassi, Kolkata and Orissa in India.

A leading manufacturer of flat, rounds and long products including value

added products with total steel value chain right from Coal Mining,

Billets, HR Coils, Pig Iron, CR Coils, GP/GC, Precision Tubes, Black

Pipe/GI Pipe, Cable Tapes, Tor Steel, Wire Rod Bright Bars and Special

Alloy Steel.

Successfully commissioned 2.3 Million TPA Greenfield Steel and Power

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Plant in Orissa with HR Coil making facility

— First in Private Sector in the State of Orissa. For the Orissa plant,

technology and equipments are procured from world-renowned

companies like Lurgi from Germany, ABB Ltd., SMS Siemag etc.

Bhushan is selling its Value added range of products in Secondary Steel

through a large distribution network in India (comprising more than 50

sales offices) and Abroad.

A rock-solid foundation combined with continuous upgradation and

innovation has ensured that we have constantly surpassed our goals. Ourend-to-end portfolio offers a wide spectrum of products with consistently

superior quality. In addition to our export thrust, we supply to fast-

growing sectors like automotive, white goods, construction, furniture,

fasteners,telecommunication,etc.

Among our major and valued customers in India are Hero Honda,

Honda Scooters, Yamaha Motorcycles, JBM, Bajaj Autos, Polar

Industries, GE Motors, Amtek, Hindustan Motor, Hero Cycles, Avon

Cycles, Atlas Cycles, Delton Cables, Finolex Cables, Sterlite,

Paramount Cables, TVS, Suzuki, Omax Auto, Maruti Udyog Ltd. etc.

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Bhushan's products are being exported to Austria, Bhutan, Beinhoa

City, Belgium, Congo, Cotondu, Dubai, England, France, Freetown,

Gambia, Kuwait, Lebanon, Liberia, Luanda, Malaysia, Monrovia,

Nepal, Nigeria, Oman, Singapore, Saudi Arabia, Sri Lanka, South

Africa, Senegal, Sierra Leone, Switzerland, Tanzania, Tamatave,

U.A.E and Vietnam.

GROWING FROM STRENGTH TO STRENGTH:

1970 - Started with very small initial outlay for manufacturing Door

Hinges & later on, Rail Track

Fasteners.

1973 - Manufacturing facilities

set up for Tor Steel and Wire

Rod in Chandigarh.

1981 - Rolling Mill Project

commissioned at Chandigarh for Round and Narrow Strips.

1985 - Backward Integration Project for Steel Melting facilities.

1986 - Upgrading of Mini Steel Plant with continuous casting and ladle

furnace facilities.

1997 - Commissioning of Narrow Width Cold Rolling Project at

Chandigarh.

1998 - Commissioning of Precision Pipe Project at Chandigarh.

2001 - Commissioning of Cold Rolling & Galvanizing Complex at

Kolkata.

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2002 - Addition of narrow width Cold Rolling facilities at Kolkata.

2003 - Expansion of wide width Cold Rolling facilities, ERW Water

Pipes & Tubes down stream facilities at Kolkata.

2004 - Further expansion of Cold Rolling facilities at Kolkata.

2005 - Commissioning of Orissa Project Phase-I consisting of 4 DRI

Kilns, Steel Making Facilities, Coal Washery and 100 MW Power Plant.

2007 - Commissioning of further expansion of Orissa Project Phase-II

consisting of HR Coil Mill, Steel making, Blast Furnance, Sinter plant,

Coke oven plant, Oxygen plant and Lime & Calcining Plant.

2009 - Commissioning of 3.5 million tpa Coal Washery, 146 MW Power

Plant and 0.3 million tpa Sponge Iron under Phase III of Orissa Project.

2010 - Commissioning of 130 MW Power Plant and Electric Arc Furnace

under Phase III of Orissa Project and further expansion of Orissa Project

under Phase IV consisting of 6 DRI Kilns, 130 MW Power Plant, Steel

Making Facilities,2nd CSP Caster & 6th strand along with Tunnel

Furnace, Oxygen Plant, Lime Calcining with downstream facilities - Cold

Rolling, Galvanizing, Galvalume, Colour Coating, Precision Tube &

Black Pipe/GI Pipe.

2011 - Commissioning of two DRI Kilns, Electric Arc Furnace, 2nd CSP

Caster & 6th Strand along with Tunnel Furnace, Cold Rolling Mill

Complex and Galvanising under Phase-IV of Orissa Project.

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MISSION AND VALUES

Our Mission is to achieve clear identity and leadership globally in Steel

production and distribution by integration of complete chain of production

starting from captive iron ore to end user Steel products.

Our revolution in Steel production has helped us to carve a niche unique only to

a market leader. Every year passes by with new value additions and more

accolades from our customers - Locally and Globally. Our rising chart in

respect of all-important parameters of production and finance is a testimony to

our claim.

In pursuing our mission, we at Bhushan Power & Steel Ltd. are guided by the

following values -

Quality - To be the best in quality. We aim and achieve excellence.

Technology - State of the art technology and product enrichment by continuous

Research and Development.

Customer Friendly - Our products are world class and more and more clients

are appreciating and using our products. We also undertake customized

products with values addition and enhancement.

Corporate Governance - We comply with all applicable laws and regulations.

We believe in maintaining clean environment and conservation of natural

resources. We contribute towards betterment of our staff and provide them with

best of facilities.

Environment Protection and Practice - We are adopting and implementing

pollution control measures as a matter of policy.

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Company Commitments -

To improve the quality of our products and complete integration of

various stages of production. To be conscious towards quality and pricing of our products. We strive

by continuous research and development to make our products world

class, having distinct identity and uniqueness. Our customers get best

value for their money.

To run the company profitably year after year.

A workforce motivated, skilled and well looked after.

A workplace safe, secure and hygienic.

To make our Environment Clean and healthy.

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ROLLING

Objective-To perform rolling process on a lead bar in order to observe the

change in both the cross-sectional area and the general shape.

Theory-

Definition

Flat rolling or Rolling is defined as the reduction of the cross-sectional area of

the metal stock, or the general shaping of the metal products, through the use of

the rotating rolls. It allows a high degree of closed-loop automation and very

high speeds, and is thus capable of providing high-quality, close tolerancestarting material for various secondary sheet metal working processes at a low

cost .

FIGURE1.3 – SCHEMATIC DRAWING OF ROLLING PROCESS

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The rolls rotate as illustrated in Figure 1.3 to pull and simultaneously squeeze

the work between them. The basic process shown in Figure 1.3 is flat rolling,

used to reduce the thickness of a rectangular cross section.

FIGURE1.4-VARIOUS CONFIGURATIONS OF ROLLING MILLS:

(a) two high, (b) three high, (c) four high, (d) cluster mill, and

(e) tandem rolling mill

Various rolling mill configurations are available to deal with the variety of

applications and technical problems in the rolling process. The basic rolling mill

consists of two opposite rotating rolls and is referred to as a two-high rolling

mill (Figure 1.4a). In the three-high configuration Figure 1.4(b), there are three

rolls in a vertical column, and the direction of rotation of each roll remains

unchanged. To achieve a series of reductions, the work can be a passed through

from either side by raising or lowering the strip after each pass. The equipment

in a three-high rolling mill becomes more complicated, because an elevator

mechanism is needed to raise and lower the work .

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Roll-work contact length is reduced with a lower roll radius, and this lads to

lower forces, torque, and power. The four-high rolling mill uses two smaller

diameter rolls to contact the work and two backing rolls behind them. Another

roll configuration that allows smaller working rolls against the work is the

cluster rolling mill.

To achieve higher throughput rates in standard products, a tandem rolling mill is

often used. This configuration consists of a series of rolling stands. With each

rolling step, work velocity increases, and the problem of synchronizing the roll

speeds at each stand is significant.

General Overview of Process

The primary objectives of the flat rolling process are to reduce the cross-section

of the incoming material while improving its properties and to obtain the

desired section at the exit from the rolls. The process can be carried out hot,

warm, or cold, depending on the application and the material involved. The

rolled products are flat plates and sheets. Rolling of blooms, slabs, billets, and

plates is usually done at temperatures above the recrystallization temperature

(hot rolling). Sheet and strip often are rolled cold in order to maintain close

thickness tolerances.

Basically flat rolling consists of passing metal between two rolls that revolve in

opposite directions, the space between the rolls being somewhat less than the

thickness of the entering metal. Because the rolls rotate with a surface velocity

exceeding the speed of the incoming metal, friction along the contact interface

acts to propel the metal forward. The metal is squeezed and elongated and

usually changed in cross section. The amount of deformation that can be

achieved in a single pass between a given pair of rolls depend on the friction

conditions along the interface. If too much is demanded, the rolls will simply

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skid over stationery metal. Too little deformation per pass results in excessive

cost.

Rolling involves high complexity of metal flow during the process. From this

point of view, rolling can be divided into the following categories :

Uniform reduction in thickness with no change in width: Here, the

deformation is in plane strain, that is, in the directions of rolling and

sheet thickness. This type occurs in rolling of strip, sheet, or foil.

Uniform reduction in thickness with an increase in width: Here, the

material is elongated in the rolling direction, is spread in the width

direction, and is compressed uniformly in the thickness direction. This

type occurs in the rolling of blooms, slabs, and thick plates.

Moderately non-uniform reduction in cross section: Here, the metal is

elongated in the rolling direction, is spread in the width direction, and is

reduced non-uniformly in the thickness direction.

Highly non-uniform reduction in cross section: Here, the reduction in the

thickness direction is highly non-uniform. A portion of the rolled section

is reduced in thickness while other portions may be extruded or increased

in thickness. As a result, in the width direction metal flow may be toward

the center.

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HOT ROLLING: The distinctive mark of hot rolling is not a crystallized

structure, but the simultaneous occurrence of dislocation propagation and

softening processes, with or without recrystallization during rolling. The

dominant mechanism depends on temperature and grain size. In general, the

recrystallized structure becomes finer with lower deformation temperature and

faster cooling rates and material of superior properties are obtained by

controlling the finishing temperature .

Hot rolling offers several advantages :

Flow stresses are low, hence forces and power requirements are relatively low,

and even very large workpieces can be deformed with equipment of reasonable

size.

1) Ductility is high; hence large deformations can be taken (in excess of

99% reduction).

2) Complex part shapes can be generated.

The upper limit for hot rolling is determined by the temperature at which either

melting or excessive oxidation occurs. Generally, the maximum working

temperature is limited to 50°C below the melting temperature. This is to allow

the possibility of segregated regions of lower melting material [4].

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COLD ROLLING: Cold rolling, in the everyday sense, means rolling at

room temperature, although the work of deformation can raise temperatures to

100-200°C. Cold rolling usually follows hot rolling. A material subjected to

cold rolling strain hardness considerably. Dislocation density increases, and

when a tension test is performed on this strain-hardened material, a higher stress

will be needed to initiate and maintain plastic deformation; thus, the yield stress

increases. However, the ductility of the material – as expressed by total

elongation and reduction of area – drops because of the higher initial dislocation

density. Similarly, strength coefficient rises and strain-hardening exponent

drops. Crystals (grains) become elongated in the direction of major deformation

.

Cold rolling has several advantages :

1) In the absence of cooling and oxidation, tighter tolerances and better

surface finish can be obtained.

2) Thinner walls are possible.

3) The final properties of the workpiece can be closely controlled and, if

desired, the high strength obtained during cold rolling can be retained or,

if high ductility is needed, grain size can be controlled before annealing.

4) Lubrication is, in general, easier.

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ROLLING PROBLEMS AND DEFECTS:

The main problem during rolling process is the calibration of rollers. This

calibration faults may occur in case of used bearings and may affect thethickness of parts. A simple classification is as here below:

a. Lengthwise Occurring Defects

Change of rollers speed

Material temperature

Roller temperature

Inlet thickness

Material properties

Eccentric and conical rollers

Used bearings

b. Transversally Occurring Defects

Parallel position of rollers

Surface geometry of rollers

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ADVANCED TECHNOLOGY IN SKIN PASS ROLLING:

The increased requirements demanded of cold-rolled strip in terms of

mechanical properties and surface quality have meant that skin pass rolling, as

the last step in the process chain, has become more important. New

developments in control of flatness and surface quality, together with increased

plant flexibility to handle a diverse range of products are described.

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Against the background of a global market, rolling-mill owners are under

constant pressure to cut their production costs and to open up new market

segments with the help of innovative products. At the same time, requirements

in terms of strip quality, such as thickness and flatness tolerances, surface

structure and mechanical properties, are becoming increasingly strict.

SMS Siemag, as a provider of complete solutions for rolling mill equipment, is

faced with the challenge of taking appropriate measures to help achieve these

targets. Therefore, conducting continuous and wide-ranging development

activities is indispensable to SMS Siemag. Long-standing solutions need to be

questioned and new technologies examined for their usability and benefits in

rolling mills.

With regard to skin pass rolling, our main areas of development are:

` Improving flatness and surface quality

` Increasing flexibility to handle high-strength material such as DP1000 as well

as very soft material like interstitial-free (IF) grades

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` Improving the automation by process models and control systems based on

innovative online measurement devices

USE OF LOW VOLUME LUBRICATION AND LIQUID

NITROGEN :

SMS Siemag has developed, together with Air Products, REBS and C D

Wälzholz, a new lubrication and cleaning concept involving a combination of

low-volume lubrication and the utilisation of liquid nitrogen in skin pass rolling.

This concept significantly improves the strip surfaces and minimises operating

costs.

The low-volume lubrication system applies the lubricant in the skin-pass stand

entry. This reduces the friction in the roll gap and hence the roll force, and

improves flatness while using a minimum amount of lubricant. The liquid

nitrogen in the exit covers both the strip and the roll

This method has the following advantages:

` Clean and dry strip surfaces and thus lower susceptibility to rust

` Clearly reduced efforts in the downstream steps for cleaning the strip surface

` Extended work roll service lives

Low-volume lubrication: Considering the fundamentals of lubrication

according to Stribeck , cold rolling takes place in the area of boundary

lubrication. This means the roll and strip come into occasional contact.

Surplus lubrication with higher speed causes more lubricant to be drawn into the

roll gap, hence roll and strip are better separated by lubricant pockets, but this

causes imprints of the lubricant on the strip surface.

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With low-volume lubrication, which applies around 0.3 – 0.4ml/m, only a film is

produced, which is thinner than the combined roughness of the strip surface and

roll, and so these imprints are avoided.

The major components of the low-volume lubrication system are very compact

and comprise the nozzle beam, a volume controller and the tank, pump and

control unit. Two nozzle beams are installed: one for the top and one for the

bottom strip surface. Due to the small amount of lubricant, its equal distribution

can only be ensured by atomising it with compressed air. The volume controller

ensures a constant flow rate during operation. Three configurations are

available: one controller for each nozzle, one for a group of nozzles and one for

a single nozzle beam.

Figure also shows the assessment of the strip surface quality rolled with and

without low-volume lubrication. In both cases the same material was rolled. The

typical imprints of the lubricant cannot be observed and the strip surface quality

is fully comparable.

In addition, low-volume lubrication means that roll force is reduced as even a

very small amount of oil causes a remarkable decrease in roll force . By

varying the amount of oil over a considerable range the roll force can be

adjusted. This opens up new options in controlling skin pass rolling.

LIQUID NITROGEN: Typical installation consists of vaporiser and nitrogen

tank, which are installed outside the mill building. The tank is connected to the

nozzle system via a vacuum jacketed line and supply is controlled via valves .

To assess the strip surface quality using liquid nitrogen, the same material was

skin-passed under different operating conditions . In the pass with emulsion

(left), clear impressions of the lubricant were found. They make the surfaces

appear less bright. The roll abrasion in dry skin pass rolling has a similar effect

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REWIND CUM TRIMMING LINE:

Built from the basic elements of the compact trimming line, the modular line

mechanically trims the edges through chip removal process. Any desired

dimension is possible depending on strip width and thickness. The number of

tools operating simultaneously is variable.

Specification :

Type of

Line

Tight Line With

Driven Trimmer.

Material CRFH / CRCA.

Strip

Thickness2.0 MM.

Strip Width 1250 MM.

Coil O.D. 2000 MM.

Coil Wt. 25 T.

Line Speed 500 MPM.

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CUT TO LENGHT LINES:

Precision cut-to-length lines are meant for ferrous and non-ferrous rolling mills,

service centers, toll processors, industrial and automotive users. Cut to length

lines perform a variety of operational functions including cut sheet levelling,

edge trim, cut to length, and stack sheets and plates. The application varies from

the heaviest hot rolled plate coils to light gauge cold rolled steel, aluminum and

copper alloys - often with sensitive or polished surfaces. Multi-blanking lines

with options such as continuous 'slitting and shearing' with electronic stacking

facility, are also available.

Specification :

Type of

Line

Loop Start Stop.

Tight Start Stop.

Material Hot Rolled M.S.

CRFH / CRCA /

GALVANIZED /

COLOUR COATED.

Strip

Thickness

6.0 MM. (H.R.)

3.0 MM (C.R.)

Strip

Width1650 MM.

Coil O.D. 2000 MM.

Coil Wt. 30 T.

Line

Speed

30 MPM. (H.R.)

100 MPM (C.R.)

No. of

Cuts

15 Cuts / Minute -

(H.R.).

40 Cuts / Minute -

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(C.R.).

Sheet

Length

6000 MM (H.R.)

5000 MM (C.R.)

FEATURES:

Multi-Roll precision leveller with Back - up roll banks.

Pack lifter & shifting Trolley arrangement.

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COIL BUILDUP LINES:

The coil build-up lines are used for side-trimming of the strips and also provide

the coils with leader strips that can be reused for optimization of the yield. With

suitable inclusion of welder, these lines can be used for building up bigger coils

from small coils, with roll-able weld.

VARNISH COATING LINES:

Varnish coating lines are highly resistant to corrosion

and have long life. They are equipped with motorizedfine adjustments of the rolls, enabling precise

positioning. Linear position sensors are placed for reproducible setting of stored

reference values even if the product is changed. Pass-line roll is used to keep the

strip flat for two-side coating. Mobile coater heads are also used to facilitate roll

and vat removal, cleaning and maintenance work, and presetting of specific

production parameters.

SKIN PASS MILL:

These skin pass mills are specifically designed for

manufacturing sheet / strip of medium hardness or to

provide finish pass. The Rolls are made of alloy steel

& have high hardness, which is generally up to 65 HRC or more. For increasing

demands with respect to strip flatness, elongation and roughness, especially for

hard material grades, skin-pass mill is an ideal solution due to higher rolling

forces and torques that can be achieved in this case.

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PICKLING LINES:

These pickling lines can process strips varying from

1.0mm to 12.0mm thick and 200mm to 2000mm

wide. Picking lines process one coil at a time,

therefore eliminating the need for joining strips. This process allows immense

flexibility of operation & also ensures easy operation and maintenance. As

accumulators are not required in these lines, thus making them cost effective in

nature. These pickling lines are capable of producing between 200,000 to

1,000,000 Tons per annum.

Specification :

Type of

Line

Push -

Pull.

Material

Hot

Rolled

M.S.

Strip

Thickness

6.0

MM.

Strip

Width

1250

MM.

Coil O.D.2000

MM.

Coil Wt. 25 T.

Pickling

Cascade

with 2 /

3/ 4

Tanks.

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Rinse

Multi

Stage

Cascade

Hot

Rinse.

Pickling

MediumHCL.

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GALVANISING LINES:

We offer hot-dip galvanizing lines. The lines

manufactured by us are furnace type, heat to coat

type or wet flux type. Efficient air-knives control the

thickness of coating with great precision, either through manual settings or

through automatic coat control systems. The materials can be pickled hot rolled

steel, cold-rolled steel of CQ, DQ quality & full hard in nature.

Type of

Line

Wet flux.

non-ox

furnace.

Material C.R. full

hard.

Strip

Thickness

0.6 mm.

(wet

flux)

1.5 mm

(furnace)

Strip

Width

1250

mm.

Coil O.D. 1850

mm.

Coil Wt. 22 mt.

Line

Speed

90 mpm.

(wet

flux)

150 mpm

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(furnace).

Coating 90 - 250

gms/m2.

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ELECTROLYTIC CLEANING LINE:

Utilizing a performance enhanced, low-temperature, high volume, updraft re-

circulating hot air design, the Electrolytic cleaning line is ideal for refreshing

steel products and other metallic mater. The Electrolytic cleaning lines are the

ideal wet cleaning complement for advanced Electrolytic components.

Specification :

Type of

Line

Electrolytic

Cleaning

with Alkali

Material

Cold

Rolled

M.S.

Strip

Thickness2.5 MM.

Strip

Width1650 MM.

Coil O.D. 2000 MM

Coil Wt. 30 T.

Line

Speed200 MPM.

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ANNEALING LINE:

The demand for better annealed stainless steel has

increased. Annealing is a heat-treating process

conducted under controlled-atmosphere furnace to

minimize oxidation, so that the product surface remains clean. It is very

common for continuous annealing of strip products and stainless steels.

Type of

Line

Horizontal

Tight

Line.

Material Stainless

Steel.

Strip

Thickness 1.5 MM.

Strip

Width660 MM.

Coil O.D. 1650 MM.

Coil Wt. 10 T.

Line

Speed 30 MPM.

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ANNEALING AND PICKLING FOR STAINLESS STEEL:

The heat treatment has to be specific in annealing and pickling line to find the

best compromise between strength and ductility without neglecting the surface

finish. Annealing and pickling lines (APL's) are used for the treatment of hot

rolled (HR) and cold rolled (CR) stainless steel strips.

HR Austenitic & CR strip is annealed and pickled continuously in an APL and

HR ferric strip is only pickled. Lines for HR & CR, as well as dedicated APL's

process the majority of the stainless steel production.

SLITTING LINES:

Slitting Lines have been successfully put into

operation in well-known production plants & service

centres. These lines have the capability to meet

client's demand for minimum burr, no damage to the surface, high production

capacity etc., to the fullest. The high automation level of the lines reduces the

need for operator attendance and ensures economy of operation.

Characteristic Features:

High automation level to achieve high economic efficiency

Minimum burr on strip edges due to high running accuracy of knife

arbors

No manual interferences required as the edge scrap baller is pit mounted

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PICKLING:

In semi-continuous pickling line surface oxide layer of H.R. Coils are removed

by the action of warm hydrochloric acid , which is subsequently rinsed by cold

& hot water such that pickled H.R. coils does not carry any acid & is neither

under or over pickled.

COLD ROLLING:

The process consists of reducing thickness of hot rolled coils to desired

thickness in several passes (according to set pass schedule). This results in :-

a) Closer dimensional tolerance.

b) Improved shape.

c) Improved surface.

ANNEALING:

Steel after undergoing cold rolling become very hard because of work

hardening & has got only limited use e.g. galvanizing because of loss of

ductility. In order to restore Ductility, Formability, C.R. coils are annealed in

protective Nitrogen - Hydrogen atmosphere such as to attain desired grain size

and orientation. This process results in improvement in formability related

properties & also in its microstructure.

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SKIN PASSING:

Skin passing of annealed cold rolled steel coils is carried out for following:

a) To suppress the yield point phenomenon which can cause stretcher strains on

formed component.

b) To remove the wrinkles & achieve flatness that is caused due to annealing.

c) To impart matte or bright finish depending on customers requirements.

In addition to this semi-processed electrical steels are given about 7-8% critical

reduction such as to improvise their magnetic properties.

SLITTING AND SHEARING:

After skin passing the coils are slit to the required width, by the precision

slitting machine.

The coils are further sheared to the desired length facility.

The coils / sheets thus supplied to the exact sizes for end users improve the

yield of CR rolled steel and sheets.

OILING AND PACKING:

The coils are provided with an uniform coating of special rust preventive oil to

guard against rusting, atmospheric corrosion & to allow storage for long

duration.

The oil can be easily removed in normal degreasing.

The coils/sheets are securely packed in bituminoid polyethylene lined Hessian

and tied with steel straps to avoid any damage in handling and storage.

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CONTINUOUS PICKING LINE:

After slitting the HR coils (the basic raw material), is passed through a

Continuous Pickling Line (CPL) to remove the oxides / rust or scales from the

strip surface, thereby enabling further reduction of thickness to the desired level

in the Cold Rolling Mills.

BATCH ANNEALING FURNANCE:

By annealing the cold rolled coils the desired properties in the finished coils are

obtained by heating the material to a pre-determined temperature in a protected

atmosphere and soaked for a specified time, before it is cooled to room

temperature. This gives uniform properties throughout the coil and the desired

microstructure of the finished product with a bright finish.

SKIN PASS MILL:

After the cold rolled coils are annealed, the strips are skin passed to improve theflatness and remove the superficial stresses over the strips. Anti-rust oil is

sprayed on the strip surface for protection from rust.

COLD ROLLED COILS SLITTER:

In order to obtain uniform width throughout the coil, the edges are trimmed in

the CR slitter

CUT TO LENGHT LINE:

In Cut-To-Length Line (CTL), slitted coils are sheared to the desired length as

per customer's requirement with very close tolerances.

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END APPLICATIONS OF COLD ROLLED COILS/SHEETS:

Precision Tubes

Bicycle / auto rims

Deep / Extra deep drawn auto components for auto sector

Material handling system

White goods sector

Furniture & office equipment

Various grades rolled along with their specifications and dimensional

tolerances are detailed as under:

Material Specifications

Chemical Composition (max)

Hardness (VPN)

UTS

EL %

Type C % Mn % S % P % Si % AI % Annealed QH HH FH

MPa (GL-80)

IS 513 O 0.15 0.60 0.55 0.55 - - - - - - 130 Max 115-130

140-160 160-190 - - - - - -

IS 513 D 0.12 0.50 0.40 0.40 - - - 0.02- 115 Max - - - - - - - -

- 280-420 23 MinIS 513 DD 0.10 0.45 0.035 0.035 - - - 0.06 105 Max - - - - - - - -

- 280-360 26 Min

IS 513 EDD 0.08 0.40 0.030 0.030 - - - 0.02-0.06 95 Max - - - - -

- - - - 280-360 32 Min

If Grade 0.005 0.08 - - - - - - 0.02 0.02-0.06 95 Max - - - - -

- - - - 280-360 42Min

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IS 1079 ST-42 0.25 - - - 0.05 0.05 - - - 0.02-0.06 130-140 - -

- - - - - - - 410-490 16Min

IS 7226 MC-11 (C-40) 0.35-0.45 0.60-0.90 0.04 0.04 0.15 0.35 - -

- 140 Max - - - - - - 220-280 - - - - - -

IS 7226 MC-12(C-55) 0.50-0.60 0.50-0.65 0.04 0.04 0.15 0.35 - -

- 160 Max - - - - - - 220-280 - - - - - -

IS 7226 C-62 0.57-0.67 0.50-0.80 0.04 0.04 0.15 0.35 - - -

170 Max - - - - - - 250-300 - - - - - -

IS 7226 HC-14(C-80) 0.75-0.80 0.50-0.80 0.04 0.04 0.10 0.35 - -

- 180 Max - - - - - - 270-350 - - - - - -

HROP:- HROP is available in all above grades .

DIMENTIONAL TOLERANCES:

Dimensional Tolerances as per BIS or any other international standard or as per

customer's specifications can be supplied however closer tolerances are supplied

by M/s. Avon Ispat & Power Limited.

CR Strip

Flattened Roller & Bush wire

Offered By ACIL

Offered By ACIL

Thickness in mm

0.20 to 0.50

± .02

Thickness in mm

0.50 to 1.15

± .02

0.51 to 1.50

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± .03

1.51 to 4.50

± .04S

Width (Slitted) in mm

Up to 100

± .10

Width in mm

2.20 to 5.80

5.81 to 9.00

±.05 ±.10

100 to 200

± .15

200 to 460

± .20

Unslistted in mm

- 6 , - NillLength in mm

Upto 500

+ 2, - Nill

above 500

+ 3, - Nil

CamberCoils

2 per Mtr

Camber

Coils

4 MM per Mtr

Size Range

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CR Strips Flattened Roller & Bush Wire Surface - Bright / Rough / Matt /

Edges -Slitted /Unslitted

Thickness in mm

CR-0.20 to 4.30 HROP up to 6.00

0.50 to 1.15

Surface - R.P Oiled / Dieseled / With out Oil Packing - Polythene / Hessian

Cloth packing is available on special demand VCI paper is also available for

Coils and CTL Sheets.

Width in mm

11 to 460

2.20 to 9.00

Coil ID in mm

400 and 500

400

Coil OD in mmUp to 7 kg Per mm

650 Max

Length of CTL in mm

250 to 3000

Coil Width 100

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