Steel production at compact strip pellet mill

1. STEEL PRODUCTION AT
COMPACT STRIP
PELLET MILL
Submitted by:-
SAROSH.RAHIL.RAHIM
CLASS:-ME-D
ROLL NO:-110106245
ENROLLMENT NO:-11SETME463

2. 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

3. 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.

4. 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.

5. • 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.
• INFRASTUCTURE
ESSAR 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.

6. 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).

7. 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.

8. 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,

9. 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

10. 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.

11. 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

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

13. 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.

14. 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

15. around 100 tonnes that produce steel every 40 to 50
minutes for further processing.

17. • 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.

18. • 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.

19. 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.

20. • 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.

21. 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.

22. 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.)

23. 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

24. • 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.

25. • 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.

26. • 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.

27. • 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.

28. • 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)

29. 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.

30. 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.

31. THANK YOU