Procedure

Over here we will purchase various types of Scrap and Sponge Iron, DRI (directly reduced iron), HBI (Hot Briquette Iron), Cast Iron, Pig Iron etc. that will come into trucks. These trucks are weighed at weighbridge (100 MT capacity computerized weighbridge) and then send to scrap yard where we will unload the same with the help of Electro Magnet. Then we would be tested for its relevant chemical composition and then segregated as per specification according to chemical composition and density. The scrap will be in the form of Heavy Melting, C.I. Boring, Pig Iron, M.S. Turning & Boring, Coal Base Sponge Iron, Gas Based Sponge Iron (DRI) etc.

The scrap will be taken to the Induction Furnace Platform with the help of Electro Magnet and charged into the Furnace. Here, basically recycle the steel, which is generated in our day-to-day life by means of industrial waste and other sources. When it is charged into Crucible, it will get heated due to Induction and Inductance, which is generated due to power (electricity) supplied thru the Copper Coil, which is surrounded to the Crucible. Due to this the steel scrap get melted and becomes liquid molten metal. At every 20 minutes sample is drawn and the liquid metal is tested for its chemical composition and based on that fresh additions of other metals are made. When the furnace is full of liquid metal we will take one final bath sample for testing. This continuous online testing is done with the help of a Spectrometer, Strohlein’s apparatus etc. After this the final addition of Ferro Alloys like Silico Manganese, Ferro Silicon, Ferro Manganese, Aluminum as per IS standards. Then at the temperature of 1630 degree C to 1650 degree C it is poured into ladle. The ladle will then be taken to the Purging Station to further refine the metal. Purging is done with the help of inert gases like nitrogen, argon etc. Thereafter it will be taken to the Continuous Casting Machine (CCM) where liquid metal will get converted into Billets. For further killing of various gases aluminum wire is also put with the liquid metal and drawn at the same pace as a liquid metal. Here the liquid metal passes through specially designed Italian Copper Mould Tubes to give it basic billet structure passing through the primary cooling and spray chamber. The hot liquid metal gets converted into billet. Here the water used for cooling has to be purer than even distilled water because any salt left in this will result in shortening the life of copper mould tubes. From the casting machine it moves to the withdrawal chamber and then on to the cooling bed. Here it is cut in the requisite lengths as per multiples required. Then the billets move to the rolling mill.

Billets are unloaded with the help of overhead crane in Billet Yard. Immediately drilled sample will be taken for testing purpose. After testing, if it is found ok as per IS Specification, will be issued for Rolling Process.

In Rolling Process, Billets are heated in Heating Furnace up to 1200 to 1250 degree Centigrade. Here too we use producer gas made in house which is both environmental better than coal as well as cheaper than furnace oil. Then the billet is moved to the Roughing Mill with the help of charging table and then by using Turn Table, Roller Table & ‘Y’ Table it moves on. Here, during rolling process at Roughing Mill, the front end and back end are cut to give a better finish to the rolled product. This ensures only the best material reaches the final product. Then the billets pass through the Intermediate and Continuous Mills. Here the bar moves at a phenomenon speed of 12 meters per second. Our factory has the unique capacity to roll 2 sizes simultaneously in the two finishing mills.

After the rolling process is over the material moves towards the quenching process. Here we use heat sensors, which feel & record the exact temperature of the material. This message is sent to the PLC controlled computer system, which opens the necessary valves and lets in cold water at the correct pressure and quantum to ensure the requisite amount of water, is supplied to the TMT Bar for quenching. Over cooling i.e. excess water will harden the bars making it brittle whereas under cooling that is less water would leave much desired for the quality resulting in the bar not having the required elongation %. Here at every half-an-hour samples are drawn and taken to the laboratory for various physical properties like tensile strength, yield test, 2% proof test, elongation, bend and re-bend test as well as simple parameters like section weight, shape, diameter etc. We have a regular system of conducting the pull out tests also, which is a difficult test and takes about 30 days to complete.

The rolled TMT Bars are cut online in the cooling bed in various lengths as per the customer’s requirements and are bundled and loaded into trailers. If required they are bend and loaded into trucks. A test certificate of TMT is issued with each and every consignment.

To ensure smooth running we have various in-house facilities like 100 ton UTM Machine, 30 channels spectrometer, Strohlein’s apparatus, and various other equipments like Mandrills for bend and re-bend test. Vernier Calipers and various Dimensional Inspection Instruments, outside and inside Micrometer height gauge, hot bar and using various principles of physics.

Over and above this we have a well equipped workshop with more than 16 lathe machines of various heights and beds having center height up to 1100 mm, Plano Miller 14 feet X 16 feet bed, drills, taping machines, grinders, swill grinders, CNC rib cutting machines, name embossing machine etc. etc.