MILL

PERFORMANCE
HSM- Hot Strip Mill
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REPORT
Tunnel Furnace & Rolling Mill
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Mar’10

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED 1

Mission, Vision & Values

Mission
To be amongst the World’s most admired New Generation Steel Companies: In
our products, in the manner in which we service our clients, in our work-
ethics, and in our culture of societal integration.

Vision

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To be an organization that continuously achieves economic value by
optimising resources through operational excellence enabled by technology
and driven by motivation to meet customer satisfaction.

Values

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We respect the skills and integrity of professionals.
We empower those who belong to us.
We work in tandem with our environment.
We listen to our stakeholders, be they customers or communities.
and
We build value for all our shareholders including the society we coexist with.

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Ispat Milestones
10000 Sponge Iron Capacity
Establishing downstream HR Coil ,Sinter & Blast Furnace
capacity at Kalmeshwar Addition Capacity Addition
9000

8000

First in
Gross Revenue (Rs Crores)

7000 First in India

India

First
6000
First in in

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Sponge-Iron Plant • HRC Capacity
India India capacity increased increased to
5000 to 1.2 TPA 3 MTPA
0.325 MTPA First in
Galvanized • 2.8 MTPA
India
Sheet Line 1.5 MTPA Sinter Plant
4000 HR Coil plant HR Coil
and 1260 TPD
with Compact Oxygen Plant
capacity
Strip Mill established
upgraded to
0.33 MTPA CR
3000 Coil plant at
2.4 MTPA
1.0 MTPA
Kalmeshwar

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Sponge-Iron
Plant
Colour Coating
2000
Plant
First in 2.2 MTPA Sponge Iron
1000 India Blast Furnace capacity
set-up increased to 1.6
MTPA
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89

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8

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Capacity / Operations related Events

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Hot Strip Mill In-line

The Hot Strip Mill at Dolvi is based on

• Tunnel Furnace
• CSP (Compact Strip Production) technology
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• Comprising of a emergency shear
• High pressure water descaler
• A train of 6 finishing stands
• Laminar cooling facility
• Down Click
coiler to edit Master subtitle style
• Coil handling facilities
• Mill auxiliaries etc.

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED 4

SIPOC - Mill

Manufacturing is a process that adds value to

a product.
P

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Process

TF- Heating of
slab
Caster Click
Slab Fromto edit Master subtitleRolled
style Marketing
Caster HRC Mill - Coil
Rolling of Slab

Inputs Output Customer

Process
s
Boundary
CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED 5
Manufacturing Process
Ispat DOLVI

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Key benefits of Thin Slab
CSP Hot Strip Mill

1) No central line segregation. Almost zero lamination

2) Capable of producing thinnest HRC (1.2mm) in India
3) Scale free smooth surface
4) Thermo-mechanical rolling producing wide range grades

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Tunnel Furnace –Technical Specification

• Supplier : Bricmont ( USA )

• Type : Roller Hearth
• No. : Two-Swivel Arrangement

•
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No. of Burners :
Line A
111
Line B
109
• Thermal Input M cal/hr : 27.17 26.35
• Length - metres : 185 182.4
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No. of rolls : 169Master subtitle
166 style
• Transfer Speed-mpm max.: 60 60

• Fuel : RLNG & LDO .

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED 7

Tunnel Furnace – Product Input

• Slab thickness : C1 - 62 mm , C2 - 65 mm

• Width : 900 – 1560 mm

• Slab Length : 42 M (max)

•
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Steel grades : LC/MC/HC steel, Micro alloyed steel, LPG, Corten, API

• Slab speed from caster : 2.2 – 6.5 m/min

• Click to :edit
Slab delivery speed Master subtitle style
15 –36 m/min

• Temp. of slab inlet : 975 – 1130° C

• Temp of slab outlet : 1150+ 7° C

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED 8

Mill – Specification

1. Emergency shear
• The shear is provided to divide the thin slab in two pieces once a
breakdown/cobble occurs in the mill and further rolling is not possible.

• Knife length :1800 mm

• Knife opening :350 mm from top of roller table

•
•
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Top Knife
Bottom knife
:V shaped, concave
:Straight, convex
• Cutting force : 5500 KN
• Slab temperature :min 600°C
• Scrap length :max 600 mm
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Min. cutting interval time :10 seconds

Entry and exit roller of shear:

• No. of rollers :1 at entry side, 1 at exit side
• Roller dimensions :dia 360 mm x 1800 mm barrel length
• Table speed :1 mtr / second

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED 9

Mill – Specification

[Link] Device:
Removal of scale from top of strip surface by means of high pressure
water jet .

LP headers 2: Pressurized by 5

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pumps (URACA make).
Q= 463 x 5 liters per minute, max. 250
Bar at nozzles

HP headers 2: Pressurized by 6
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pumps (URACA make) ,
Q = 463 x 6
LPM, max 400 bar at nozzles.

Image of descaler

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Mill – Specification

3. Mill Stands :
• Distance between Mill Stands : 5500 mm
• Input Slab Width : 900 – 1560 mm
• Strip Thickness : 1.4 – 25 mm
• Coil Out Side Diameter : 1000 – 1950 mm
•
•
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Coil In Side Diameter
Max. Coil Wt.
: 760 mm approx.
: 28 tons
• Max. Specific Coil Wt. : 18 kg / mm
• Max. Slab Length : 42 metres
6-stands of 4-Hi rolling mill

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• F1 to F4 : 805 max. 729 mm min
• F5 & F6 : 605 max. 539 mm min
• Back up Roll Dia:
• F1 to F6 : 1450 mm max 1350 mm min
• Work roll barrel length : 1950 mm
• Back up roll barrel length : 1750 mm

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Mill – Specification

Roll separating force:

• F1 to F4 :40 MN
• F5 & F6 :32 MN
• Strip cooling method :Laminar cooling
• Number of zones :16 normal zones and 8 fine zones
•
•
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Coiler Type
Width adjustment
: Down coiler with step control
:850 – 1650 mm

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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Mill – Specification

4. Run out Roller Table

The run out roller table is provided to convey the strip from the
finishing stand F6 to the down coiler.

• Table length : 79.50 M (Between Centerline

F6 and Down coiler 1)
•
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Number of rollers
Roller diameter
: 240
: 260 mm
• Table speed max : 15 mtr/sec

• Bearings (centrally greased) : On drive side self aligning roller

bearings, On non-drive side cylindrical roller bearing
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• Cooling : Spray

• Pressure : 10 bar

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Mill – Specification
5. Laminar Cooling Banks
• Water flow volume : 4900 m3/hr
• Water pressure : 0.7 Bar for normal and
fine zones and 10 Bar for spray zone
• No. of swiveling groups : 07
• Total length of the cooling system is approx
: 42 meters
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No. of transverse sprays 10 Bar.

• Laminar Cooling Zones 01 Compact Cooling

22 Micro Zone
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Trim Zone subtitle style
To roll value added steels like DP Steel etc., special cooling
arrangements have been made and we are
in the process to link it with our level II cooling
master for fine control.

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Mill – Specification

6. Down Coiler Type - Retractable with Step Control

• Mandrel :Expanded Dia 762 mm : Collapsed
Dia 727 mm

• Wrapper rolls (3 nos) :Dia 380mm x 1700 mm

barrel length

•
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:
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Clearance in coiler housing 2250 mm

• Speed max. :15 mts/sec

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• Coil weight : 28.5 Tones max, max 18 Kg/mm

• Coil dia :1000 –1950 mm

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Stands Design Are “State Of The Art” Technological Control
Systems Such As:

• Hydraulic gap control

• Thickness control system
• Hydraulic lopper control
• Work roll bending mechanism
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Profile and flatness control system
• MMI system

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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Slab v/s Strip Thickness

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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

SMS EQUIVALENT GRADE

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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Product Tolerances ( SMS Gurantees )

• Coil Telescopicity - Body : ± 08 mm

• Strip Thickness - Body

1.2 – 3.0 mm : ± 28 µm
3.1 – 4.5 mm : ± 36 µm

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4.6 – 9.0 mm
> 9.0 mm
:
:
± 44 µm
± 60 µm

• Strip Flatness - Body

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1.2 – 2.0 : subtitle style
15 – 30 I Units
> 2.0 mm : 12 – 20 I Units

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Product Tolerances ( SMS Gurantees )

• Strip Profile C25 : ± 20 µm

against set value C40 : ± 15 µm

• Strip Width : + 8 mm

•
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Finishing Temp.
( except for special quality steels )
: ± 20 o C

• Coiling Temp. : ± 15 o C
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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Product Guarantee in relation to dual line operation

Differences between the strips from both lines should not

exceed for :

• Final Thickness : 30 % but < 2.0 mm

•
•
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Strip Width
Strip Profile
:
:
100 mm
20 micron
• Coil Yield Strength : 15 %
• Final temperature : 25 oC
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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

VALUE ADDED GRADES

ESTABLISHED VALUE ADDED GRADES

• SH41
• API X65
• LPG
• TR 34, 38, 45, 46
• ST 41A, 41C, 41G, 46C, 49
• CG 04H

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•
•
•
ASTM - A 570
Thinner Gauges 1.2, 1.3, 1.4, 1.5 mm
EDD CR02A
• API 5L X70
• MC 45, ML 55

VAG UNDER DEVELOPMENT

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• API 5L X-J-55
• D P Steel ( wheel rim )
• Boiler Grade
• CE 01D / CE 01C
• Corten 1.6 mm in 1000 mm width
• ASTM-A-607 (Purlin Grade)
• IF STEEL ( CR01A)

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Integrated Systems

Automated processes built to deliver Customer Value

• Level-II automation ensuring auto correction in the production process

enabling prevention of generation of defects in process.
• Parsytech detects surface condition continuously on-line and gives constant
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feedback through Level-II to control surface quality.
• MySAP and PPMS system integration enables close adherence to delivery
commitments.
• MySAP CRM along with dedicated cell manages voice of customer (VOC)
through cross functional team (CFT) approach, addressing customer needs
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and ensures customer driven policies and activities.
• Product Development methodology includes technical alliances with leading
Technical Institutes in the World, facilitating development of customized
products.

Such best of practices aimed at Delivering Total Customer Value.

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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

ISPAT
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to edit Machinery
titleSector
style
Adding Value
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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Ispat steel for Machinery Sector

Unique features of Steel produced through Thin Slab-CSP

Steel from CSP route with low carbon micro-alloyed through Thermo-
Mechanical Rolling (TMR) is advantageous over conventional steel (CSC route)

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– Better weld ability (Carbon equivalent is lower)

– Higher toughness (Charpy V-Notch Impact value higher)

– More ductility* (% elongation and bend)

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* Applicable based on end use or specific requirement of the customer.

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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Ispat steel for Machinery Sector

Factors behind the Key Strengths:

Thermo Mechanically Rolled Steel with Low Carbon and Micro-alloying

HIGHER STRENGTH (effect of micro-alloying) 1. Lower weight of Steel gives

equal strength to components

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HIGHER DUCTILITY (due to cleaner steel, lower carbon)
BETTER FORMABILITY (lower Ys/Ts ratio, finer grain)
2. Longer life of components by
extended fatigue free life
3. Stronger HAZ (Heat Affected
HIGHER TOUGHNESS (due to grain boundary refinement Zone) gives more robustness
) to structure

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BETTER WELDABILITY (effect of lower carbon)

1. Strengthening achieved by grain refinement and precipitation

strengthening
2. Hot strength & corrosion resistance can be improved by microalloying by
Cr, Ni & Mo

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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

ISPAT
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to edit Machinery
titleSector
style
Grades & Applications
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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Key Grades & Applications

Hot Rolled Steel

APPLICATIONS ISPAT GRADE Equivalent
IS 5986 Fe 360
JISG3101 SS330
SG37AL/SG37AT
Fabrication of Agricultural, Industrial and Mining DIN17100 St 37.2
machinery parts like Bins, Hoppers, Chutes, Etc. EN10025 S235 JR G2
DIN17100 St 44.2
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Boiler & Pressure Vessel Parts
SG41AL/SG41AT

MC26BQ
EN10025 S275 JR
ASTM 516 Gr.60, Gr.70
Machine parts, Panel SH41AM JISG3113 SAPH400
IS 2062 A, B, C
ASTM A570 D Gr. 45
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Agricultural machinery Parts
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Machinery foundations, Base plates, Mining and
ST41AL/ST41AT JISG3101 SS400
DIN17100 St 44.2,
EN100025 S275JR,S275JO
ASTM A570 Gr.50
ST46CL / CT
Mining & Industrial machinery Parts requiring JISG3113 SAPH440
higher strength under static and dynamic DIN 17100 St 52.3
loading ST52AL / AM / AT
EN 10025 Fe 510 B

ST54AL/AM / AT IS 8500 Fe 540 B

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Steel Features

FEATURES & TOLERANCES

Profile Crown: + 40 to 70 Micron at C 40

Flatness: 200 to 250 Units

Thickness Tolerance: Up to 4.0mm +/- 0.075mm, 4.0-10.0mm +/- 0.10mm,

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Above 10.0mm +/- 1% t

Width Tolerance: + 15 / - 0mm

Coil ID: 762 +/- 20mm

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Weight: 18 Kg / mm max of width for Coils

All above material available in HRPO/HRSPO

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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Key Grades for Machinery Parts

Cold Rolled Steel

APPLICATIONS ISPAT GRADE Equivalent
Drawing D CR4 / SPCC

Machinery housings and Panels Deep Drawing DD CR3 / SPCD

Extra Deep Drawing EDD CR1 / SPCE

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FEATURES & TOLERANCES

Coil weight: 10.0 mt max , Packet Weight – 3.0 mt max

Click
Finish: to edit
Bright – 0.50Master subtitle
Ra max, Matte style
– 0.60 -- 1.60 Ra

Length: 500-1500 mm, Tolerance : +2/- 0 mm,

Above 1500 mm Tolerance: +3/ -0 mm
Thickness Tolerance: up to 1.0mm +/- 0.03 mm, up to 2.0 mm +/- 0.05 mm,
up to 3.0 mm +/- 0.10 mm
Width: 200-1250mm, Tolerance: Mill Edge (+ 6.0 / - 0 mm),
Trimmed Edge (+1.0mm/-0mm)

Coil ID: 508 mm

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Key Grades for Machinery Parts

Galvanized Steel
APPLICATIONS ISPAT GRADE Equivalent
Drawing (D) JIS G3302 SGCC

Air handling units , Machinery panels. Deep Drawing (DD) JIS G3302 SDCD

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FEATURES & TOLERANCES

Coil weight: 10.0 mt max , Packet Weight – 3.0 mt max

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edit Master subtitle style
90 GSM TO 450 GSM

Galvanized Finish: Regular Spangles, Suppressed Spangles, Zero Spangles.

Surface Treatment: Chromated & Non Chromated, oiled & unoiled

Length: 500-1500 mm, Tolerance: +2/- 0 mm, Above
1500 mm Tolerance: +3/ -0 mm
Width: 200-1250mm, Tolerance: Mill Edge (+ 6.0 / - 0 mm), Trimmed
Edge (+1.0mm/-0mm)
Coil ID: 31
508 mm
CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED
ISPAT
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to edit Machinery
titleSector
style
Some Examples
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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

 Indian Machinery Industry

[Link] Equipments
HRS CRS GP CCS
Product Applicability
 
2 3
Power Transmission Machinery: 1
Transformer Tank

Power Distribution Machinery: 2

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Switch Gear Parts
Electrical Panel Box 3

Power Generation Machinery: 4

Generator set

1 Click to edit Master

4 subtitle style

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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

 Indian Machinery Industry

[Link] Equipment
HRS CRS GP CCS
Product Applicability

3
Water Storage Tank 1

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Boiler Tubing 2

Pressure Vessel 3 Pressure Vessel

1 Click to edit Master subtitle style

2

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Indian Machinery Industry

3. Construction Equipments
HRS CRS GP CCS Product Applicability


Forklift 1 1

Loader Click to edit Master title style

2

Tracked Excavators 3

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3

2
CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED
Indian Machinery Industry

[Link] Equipments
HRS CRS GP CCS
Product Applicability
 
1
Overhead Crane 1

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Belt Conveyor 2

Chain Conveyor 3

3
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CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED

Click toTHANK
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YOU title style

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Let us work together to achieve the common goal of the company

CONFIDENTIAL: PROPERTY OF ISPAT INDUSTRIES LIMITED 37