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8/3/2019 Steel Plant Tech Latest
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MECON LIMITEDMECON LIMITEDMECON LIMITEDMECON LIMITED
TECHNOLOGICAL DEVELOPMENT
&PROFITABILITY
IN STEEL INDUSTRIES
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STEEL
INDUSTRY
Global Highlights:
Global steel production in 2008 decreased by 1.1 %(Production in 2008 – 1330 Mt, 2007 – 1343 Mt)
World steel production in May, 09 (95.6 Mt) decreasedby 20 % compared to May, 08 (120 Mt). However,there is steel production increase from 85 Mt inJanuary, 2009 to 95.6 Mt in May, 2009
Chinese steel sectors facing over capacity, mayrestrict production to 460 Mt – 500 Mt in 2009
Other foreign producers have cut production by 40 %
There is a 30 % decline in World steel exports
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Period Production(in Mt)
Consumption(in Mt)
2005 – 06 44.5 43.9
2006 – 07 50.1 49.7
2007 – 08 52.6 54.5
2008 - 09 e 53.1 56.0
Recent Growth of Indian Steel
Industry:
Source : Steel Scenario Statistical Year Book
India’s position in Global Crude Steel
Production:
49.4
1251
53.1
1351
55.1
1330
22.7
448
0
200
400
600
800
1000
1200
1400
2006 2007 2008 2009
January – May,
2009
Rank 3
India World
C r u d e s t e e l p r o d u c t i o n ( M t )
Rank
66
5
Rank Rank
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55
68
100
53
68 70
-2
-30
0
-40
-20
0
20
40
60
80
100
120
2007-08 2011-12 2016-17
Demand, Supply & Gaps/ Surpluses Scenario in India:
(Million Tones)
D e m a n d ,
S u p p l y
S u r p l u s ( + )
G a p
( - )
Demand Supply Gaps
194263
72530
1000
3315
43560
0 50000 100000 150000 200000
Railways
Roads & bridges
Shipping
Ports
Civil aviation
Outlay (Rs crores)Source : 11th Five Year Plan
Huge Investment in Infrastructure …Planned…
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245307 289
398 383 399 372
7736 57
12398 35 89160 153 155
171157
160 14358 40 66
81108
88 65
-72 -66 -79 -91 -102 -89 -68
63 3471
5143
55 46
-200
0
200
400
600
800
1000
B r a z i l
C I S
I n d i a
J a
p a n
S o u t h K
o r e a
C h i
n a
G l o b
a la v e r a g e
531 504559
733687
648 647
Depreciation & interest Energy Others Labour Raw material
Energy credit
C o s t o f p r o d u c t i o n
( U S $ / t )
World Steel Cost Comparison
Source : prepared based on data available in World Steel Dynamics
KEY TECHNO - ECONOMIC
ISSUES…………
TECHNOLOGICAL INNOVATION IS THE KEYTO GROWTH, PROFITABILITY & SURVIVAL
TECHNOLOGY ALONE IS SAVIOUR IN ANECONOMIC SLOWDOWN ENVIRONMENT
PROFIT IS THE DRIVING FORCE FOR ALLTECHNOLOGY IMPROVEMENT
CLEAN & GREEN PRODUCTION
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CONFIGURATION OF INTEGRATED
IRON & STEEL PLANT
CONFIGURATION OF INTEGRATED
IRON & STEEL PLANT
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BENCHMARKING OF INDIAN STEEL
INDUSTRY & GROWTH POTENTIAL
Benchmark Performance Indices:
A. Integrated Steel Plants
5K – 10K+2K – 10KBOF Lining Life(no. of heats)
6K – 10K+4K – 4.5KSteel Making (blows/ yr/working converter)
350 - 400450 to 610+Coke Rate (kg/ thm)
> 1.81.2 – 1.5Sinter Plant (t/ m2/ hr)
2.5 – 3.51.3 – 2.2Blast Furnace (t/ m3/ d)
InternationalIndianParameter
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Benchmark Performance Indices:
9095+
56 - 6492.7 – 94.3
Cold Rolling MillMill Utilization (%)Yield (%)
85 - 9098.570 - 7896.3 – 97.6
Hot Strip Mill
Mill Utilization (%)Yield from Slab (%)
1.4 – 2.53.0 – 4.70.5 – 1.0
1.0 – 1.93.0 – 3.50.5 – 0.9
Cont. Casting (m/ min)SlabBilletBloom
InternationalIndianParameter
Benchmark Performance Indices:
5 – 10010 – 150
5 – 4 010 - 40
10 – 10050 – 20010 – 5030 - 60
Steel Cleanliness (ppm)(S, P, O, N)
SPON
1200 – 18002600 - 3300CO2 Emission (kg/ tcs)
4.5 – 5.56.45 – 8.5+Specific EnergyConsumption (GCal/ tcs)
InternationalIndianParameter
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Benchmark Performance Indices:
B. Electric Arc Furnace Units
0.8 – 1.50.5 – 0.7Specific Productivity(t/ hr/ MVA)
50 – 7075 - 100Tap to Tap time (min)
30 – 455 - 4 0Oxygen Consumption(Nm3/ t)
0.8 – 1.20.3 – 0.8Specific transformer capacity (MVA/ t)
100 – 250+20 – 50/ 200Furnace Size (t)
InternationalIndianParameter
Benchmark Performance Indices:Electric Arc Furnace Units….contd.
105 - 350600 - 900CO2 Emissions (kg/ tcs)
1 – 2.52.5 - 5Electrode Consumption(kg/ t)
150 – 350400 - 600Power Consumption(KWhr/ t)
InternationalIndianParameter
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Benchmark Performance Indices:
C. Coal Based DRI/ Sponge Iron Plants
Lump & PelletsLumpOre Type
50 – 10020 - 80Usage in EAF (%)
0.45 – 0.500.45 – 0.50CFIX/ FCT Ratio
0.01 – 0.02
0.06
0.02
0.07 – 0.08
S, P in DRI (%)S
P
0.75 – 0.850.75 – 1.1Net Coal Consumption(t/ DRI) (~ 25 % Ash)
0.150.015 – 0.15Module Size (Mt/ yr)
InternationalIndianParameter
Benchmark Performance Indices:
D. Gas Based DRI/ Sponge Iron Plants
90 - 9290 - 92Metallization (%)
Lump (30 %) +Pellets (70 %)
Lump (60 %) +Pellets (40 %)
Ore Type
~ 65 %65 %Fe, in Ore (%)
0.005 – 0.010.01 – 0.03S (%)
275 – 300295 - 315Natural Gas Consumption(Nm3/ t)
0.75 – 1.20.75 – 1.2Module Size (Mt/ yr)
InternationalIndianParameter
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Indian Steel Industry - Strengthand Weaknesses:
Weakness:
Blend of low/ medium and high technology mix
Very low labour productivity
Poor state grid power supply scenario
Bottleneck in infrastructure support Longer implementation time
Poor quality of raw materials
Indian Steel Industry - Strength
and Weaknesses:
Strength:
Raw material availability
Abundant quality manpower Mature production base
Positive stimuli from construction &infrastructure industry
Promising automotive industry
Stable demand
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INDIA ON THE MOVE……… India is emerging as a global player in the
steel sector only after our steel plants haveresorted to major technological upgradationsto bring our plants at par with the best in theworld.
Improved technology levels have brought usto international benchmarks.
Technology alone has improved our productquality standards comparable with the best.
TECHNOLOGIES FOR BETTER
TECHNO – ECONOMIC INDICES
Coke making area:
Generation of steam from sensible heat of hot coke
Improved coke quenching system
Proper insulated bricks in oven roof zone and door surface
Special leak proof doors to prevent heat loss Computerized optimum heating control
Sinter making area:
Base blending of sinter mix
Waste heat recovery from sinter cooler
VVVF drives in motors
Exhaust heat recovery system for sinter cooler
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TECHNOLOGIES FOR BETTER
TECHNO – ECONOMIC INDICES
Blast Furnace area:
High capacity (4060 m3) blast furnaces Phasing out of small capacity inefficient BFs Coal dust injection with oxygen enrichment Top pressure recovery turbine Heat recovery from stove flue gas Use of prepared burden in BFs Installation of improved charging system
Steelmaking & casting area: Phasing out of OHF/ THF Ingot casting route Adoption of 100% continuous casting route Adoption of thin slab casting & continuous HR finishing train Adoption of beam blank casters
TECHNOLOGIES FOR BETTER
TECHNO – ECONOMIC INDICES
Rolling Mills area:
Phasing out of soaking pits
Phasing out of primary mills (Blooming/ slabbing)
Installation of walking beam furnaces
Hot charging in rolling mills
Miscellaneous:
Hot DRI charging in EAF
Use of BOF slag for iron making
Thyristorisation of drives
Afforestation
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Benchmarking of CO2 Emission and
Specific Energy Consumption
7.03 (2003 – 04)2600 (2002 – 03)Tata Steel, India
6.82 (2006 – 07)2900 (1900 – 00)SAIL (BSP), India
6.27 (2005 – 06)2980 (1999 – 00)RINL, India
1900 (1998)Rautarukki, Finland
5.19 (2001 – 02)1845 (1999 – 00)Kimitsu, Japan
4.05 (2004)(on saleable steel basis)1300 (2000)Dofasco, Canada
4.7 (2001 – 02)
4.4 (2004)1200 (1998)
Hoogovens, Holland
(Corus Steel)
Specific EnergyConsumption
(GCal/ t crude steel)
CO2 Emission(kg/ t of Steel)Plant
ENERGY FACTORS AFFECTING
PROFITABILITY
0.4 tph+ ¼ inch holeSteam loss
0.0025 GCal/ tcs+ 1 m3/ tcsOxygen
0.042 GCal/ tcs+ 10 kg/ tcsBoiler coal
0.007 GCal/ tcs+ 10 kg/ tcsSteamconsumption
0.03 GCal/ tcs+ 10 KWhr/ tcsPower consumption
0.052 GCal/ tcs+ 10 kg/ tcsHot metal rate
0.085 GCal/ tcs+ 10 kg/ thmCoke rate
Impact on EnergyVariationParameter
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Adoption of state of the art technology
Phasing out of obsolete technology &
equipment which have outlived their
useful life and are energy inefficient
Optimum utilization of existing facilities
Improvement in energy efficiency Reduction of semis for sale by enhancing
finished steel production
Strategy for Increased Profitability
And Sustainability:
• Enhancement of production & realisation of
‘Economy of scale’ by augmenting capacity of
production of hot metal, crude steel & saleable
steel• Value addition in the product-mix
• Broadening the product-mix for higher flexibility
• Adoption of environmental friendly technology
• Creation of infrastructure to sustain further
growth in production
Strategy for Increased Profitability
And Sustainability:
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TECHNOLOGY IMPROVEMENT
&
PROFITABILITY
IN
IRON MAKING
TECHNOLOGY FOR ADOPTION IN BLAST
FURNACE IRON MAKING:
Measures for High PCI Injection
Refractory free Blast Furnaces with closedcircuit soft water cooling system & adoption
of copper staves to maximise PCI injection -1 t of PCI (US $ 70/ t) will replace 900 kg of metallurgical coke (US $ 170/ t)
Savings per t of PCI injected: US $ 83
Potential for PCI injection:
- upto 2000 m3 BF # 120 kg/ thm- for 4000 m3 BF # 180 kg/ thm
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Profitability………a/c PCI
US $ 47.0 million
(Rs. 226.0 Crores)
Upto 9000tpd
180 kg/thm
4000 m3
US $ 15.7 million
(Rs. 76.0 Crores)
Upto 4500tpd
120 kg/thm
Upto 2000 m3
Annual
Savings
Hot Metal
ProductionPCI RateBF Size
TECHNOLOGY FOR ADOPTION IN BLAST
FURNACE IRON MAKING:
Measures for TRT operation
High top pressure operation withincorporation of TRT to achieve……
Enhanced indirect reduction
Reduced fuel rate
Power generation through top pressure energyrecovery
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Profitability………a/c TRT
14 MW
5 MW
Power
Generation
US $ 12.2 million(Rs. 59.0 Crores)
2.5 atg4000 m3
US $ 4.4 million
(Rs. 22.0 Crores)1.5 atgUpto 2000 m3
Annual
Savings
Top
PressureBF Size
TECHNOLOGY FOR ADOPTION IN BLAST
FURNACE IRON MAKING:
Other significant measures:
Waste heat recovery system for hot blaststoves
Non drainable pool runners with covers Use of torpedo ladle cars for hot metal
transportation
Automation and Level – II process controls
Incorporation of VVVF drives
Centre coke charging & better burden control
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COMPARISON OF OPERATING PARAMETERS OF
MEDIUM SIZE VS LARGE SIZE BLAST FURNACES
13 – 14 W4 – 5 MWPower generated (TRT)
540 kg/ thm550 kg/ thmFuel rate
0.36 – 0.40 Cr./ m30.45 – 0.50 Cr./ m3Sp. Investment Cost
150 - 180 kg/ thm100 - 120 kg/ thmPCI Rate
2.8 – 3.1 tpa1.3 – 1.4 tpaAnnual Production
8,000 – 9,500 tpd4,000 – 4,500 tpdDaily Production
2.5 atg1.5 atgTop Pressure
34 – 36 Nos.18 – 20 NosNumbers of Tuyeres
12 – 13.5 m9 – 10 mHearth Diameter
4000 m32000 m3
Blast Furnace Useful VolumeOperating Parameters
PROFITABILITY STRENGTH OF
LARGE CAPACITY BLAST FURNACE
Less specific energy consumption
Better suited for high PCI rates
Recovery of pressure energy from blast furnace top gas
Less specific water consumption Evacuation of hot metal is relatively better since number
of tapholes are more
Less space requirement
Less specific manpower requirement
20 % lower operational cost
Lower specific capital costs than medium size furnaces
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TECHNOLOGY IMPROVEMENT
IN
SINTERING & AGGLOMERATION
Less specific power
consumption: 2KWh/ tVVVF drives
• Increase in production: 2%
• Decrease in coke rate: 2%Integrated Level - IIprocess automation
4 % increase in production
due to less generation of sinter fines
Taller bed height from
500 mm to 700 mm
Economy of
scale
achieved for
large sizedsinter plants
Cost savings
in productionof sinter: Rs.75 /t
12% increase in production
Higher undergrate
suction: 1400 – 1700
mm WCLarge sized
Sinter Plants
(>300m2) with
state of the art
technology
BenefitEffectMeasuresTechnology
MODERN TECHNOLOGIES IN SINTERING
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Increased
plantavailability
Sustenance to volatilematter and alkali content
Use of multiclone &bagfilter
Stack
emission upto20mg/ Nm3
Lower stack emission levelUse of ESP & bag filter Environmental
& pollution
control
Power savingPower generation of 0.22
KW/ t of sinter
Waste heat recovery
boiler for power
generation
Waste heat
recovery from
cooler
BenefitEffectMeasuresTechnology
MODERN TECHNOLOGIES IN SINTERING…..contd.
MODERN FEATURES FOR LARGE SIZED
SINTER PLANTS……. (FROM 180 – 500 m2)
• Higher undergrate suction of 1600 mm WC for deep bedsintering.
• Elimination of maintenance intensive equipment like hot sinter screen, quenching drum, pan conveyor, etc.
• Deep bed dip rail circular cooler (bed depth of 1600 mm)• Waste heat recovery system
• Process gas & plant dedusting by ESPs to limit stack emissionlevel upto 50 mg/ Nm3
• Process control & automation using computers
• Use of High intensity mixer for better homogenization and balling
• Energy efficient ignition furnace with multi - slit roof mountedburners.
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1. Pellets offer more uniform & better permeability to the
movement of gases resulting in smoother furnace
operation, increased production and decreased coke rate
2. Pellets have very high cold crushing strength; as such
transportation losses are almost negligible as compared to
sinter and lump ore
3. Gainful utilisation of ultra fines generated at iron ore mines
which creates environmental hazard
3. Use of high intensity mixer for better homogenization and
balling
IMPORTANCE OF IRON ORE PELLETISING
MODERN CASTING AND FINISHING
TECHNOLOGY……
………A GLIMPSE
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PROCESS STEPS FROM LIQUID STEEL TO STRIP
TECHNOLOGICAL COMPARISON OF VARIOUS CASTERS
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THIN SLAB CASTER
CASTRIP TECHNOLOGY
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GENERAL PARAMETERS OF CONVENTIONAL SLAB,
THIN SLAB AND STRIP CASTING
9196.595.6 Yield: Product to liquid steel, %
750017500105000Space requirements, m2
0.7 – 2.00.8 – 2.00.8 – 2.0Product thickness, mm
55-6545-55100Capital cost per tonne strip, %
9-1127-33100Capital cost, %
60300-400500-800Length of technological shop, m
0.21.081.8Energy consumption including hot
rolling, GJ/ t
0.040.140.2Greenhouse gas emission tonne of
CO2 per tonne of steel produced
NA50250Slab thickness, mm
8060.9-2.2Casting speed, m/min
STRIP CASTINGTHIN SLABCASTING
SLABCASTING
CASTING TYPE
PARAMETERS
Technological
Developments inRolling & Processing
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Technological Advancementsaimed at….
Superior Quality of Finished Products
Increase in Productivity
Improvement in Yield
Reduction in Energy Consumption
Reduction in Cost of Production Widespread use of Automation
Reduction in Environmental Pollution
Hot Charging
Endless / Semi-endless Rolling
Schedule Free Rolling
Slab sizing Press
Automatic Width Control
Coil box
Flat Product Hot Rolling
……Technological Developments
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Heat Shields
Profile Control & Flatness Control
Single roll drives in finishing trains
Edge Masking
Thin slab cast Rolling
Flat Product Hot Rolling
……Technological Developments
Flat Product Hot Rolling
……Technological Developments
Reduction in caster output width variation
Larger caster heat size
Slab sizing Press
Larger heat size for caster
Increase in roll life by 40%
Increase in rolling length by 50%
Schedule Free Rolling
Increase in yield – 0.5 to 1.0%
Increase in productivity – 20%
Endless/ Semi-endless
Rolling
Energy saving 80-120 Kcal/t
Reduction in storage space
Product delivery time reduced by 90%
Hot Charging
ProfitabilityTechnology
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Flat Product Hot Rolling
……Technological Developments
Improvedgeometry
and flatness
Profile control &Flatness Control
30% reduction in roll force
20% reduction in rolling torque
40% reduction in gauge in last 3 stands
Single Roll drives
Around 14% saving in fuel consumptionHeat Shields
Reduced transfer bar rejection
Reduced line length
Better lengthtolerances
Coil Box
Increase in yield by 1.5 %Better width
tolerancesAutomatic width
control
ProfitabilityQualityTechnology
Flat Product Hot Rolling
……Technological Developments
Saving in energy by 30%
Increase in yield by 2%
Thin slab cast
rolling
Reduction in yield losses due to
trimming
Improved
edge qualityEdge masking
ProfitabilityQualityTechnology
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Coupling of Pickling Lines with Tandem
mill
Laser Welding
Shallow bath pickling
Turbulent Pickling
Electrolytic Cleaning
Continuous hot dip galvanising
Cold Rolling
…..Technological Developments
Air knife with auto lip gap control
In Line Galvanneal facility
In line tension levelling
Dual Size work rolls with single drive
Electrostatic Oiling
Cold Rolling
……..Technological Developments
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Six high tandem rolling
Roll shifting
Edge drop control
Use of contoured rolls
Cold Rolling
……..Technological Developments
Cold Rolling
………Technological Developments
Lower construction cost
Lower acid consumption
Shallow bath
pickling
Lower acid consumptionGood surface
qualityTurbulent Pickling
No limitations on steel grades
Rollable welds – higher yield
Better weld
qualityLaser welding
Higher productivity
Better yield
Lower specific consumption of energy, rolls and consumables
Saving in space & crane operation
Uniformity of product
quality
Coupling of PL &
TCM
ProfitabilityQualityTechnology
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Cold Rolling
………Technological Developments
Additional product mixInline galvanneal
facility
Zinc saving up to Rs. 1000 /tUniform coating
along width as well
as length
Air knife with auto
lip gap control
Flatness up to 2 IUInline tension
levelling
Higher productivityEffective strip
cleaningElectrolytic Cleaning
ProfitabilityQualityTechnology
Cold Rolling
………Technological Developments
Uniform coating of
antirust oil for preservation
Electrostatic oiling
Imparting roughness on
strip for paintabilityDual size work roll
with single drive
ProfitabilityQualityTechnology
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Cold Rolling
……….Technological Developments
Better strip edge qualityEdge drop control
Higher roll lifeUniformity of gaugeThermal crown
control
Higher roll lifeBetter shape control
Better strip flatness and
profile
Roll Shifting &
contoured rolls
Rolling of thinner gauges of large width
Six Hi tandem rolling
ProfitabilityQualityTechnology
Cold Rolling
………Technological Developments
Better strip edge qualityEdge drop control
Higher roll lifeBetter shape control
Better strip flatness and
profile
Roll Shifting &
contoured rolls
Rolling of thinner
gauges of large widthSix Hi tandem
rolling
ProfitabilityQualityTechnology
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Use of continuous cast billets
Hot charging
Continuous mills
Finishing blocks
Reducing & sizing mill
Long Products – Wire rod & Bar Mill
……….Technological Developments
Quick roll change carpets
High speed discharge
H / V configuration in roughing &
Intermediate group
Multi-slit rolling
On line quenching & tempering
Long Products – Wire rod & Bar Mill
……….Technological Developments
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Long Product – Bar & Wire rod mills
……….Technological Developments
Increase in productivity by
50%
Consistent tolerance of
+0.1Reducing & Sizing
Mills
Gain in productivity 50-70%
Benefits – Rs. 2600 to
3000./t
Better ToleranceHigh speed
discharge
Saving of Rs 270/t
Costly alloying elements
not required
Increase in yieldstrength 150-230 MPa
On line quenching &
Tempering
ProfitabilityQualityTechnology
Continuous cast billets / blooms &
beam blanks
Hot charging
Continuous mills
H/V Convertible stands
Multi line rolling
Long Products –Section Mills
……….Technological Developments
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On-line straightening
Automatic piling & bundling
Quick roll change carpets
Breakdown stand & Tandem
Reversible mill Group
Housing-less stands
Long Products –Section Mills
………Technological Developments
Tandem cold saws
Thermo mechanical rolling
Long Products –Section Mills
…….Technological Developments
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Long Product – Section mills
……….Technological Developments
Saving in energy 40-50%Reduction in conversion cost Rs
1350-2250./t
Cast blooms &beam blanks
Avoidance of post rolling heat
treatment (savings Rs 975-1105./t)
Reduction of annealing time
(savings Rs 325-520./t)
Multi line Rolling
Higher mill utilisation
Reduced manpower
Consistentproduct quality
Housing less stands
ProfitabilityQualityTechnology
Long Product – Section mills
……….Technological Developments
Increase in mill productivity by
5 to 15%
Homogeneity of
mechanical
property & increase
in yield strength by
100 to 150MPa
Thermo-mechanical
Rolling
Saving of 68% in initial outlay
compared to continuous &
semi-continuous mills
Consistent product
qualityTandem reversible
mill group
ProfitabilityQualityTechnology
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• Brown field industry should replace old
technologies with efficient & environmental - friendly
technologies suitable to provide economy of scale and
its integration with the existing plant environment.
• Green field plants should adopt technologies with due
diligence of all promising technologies. Technologies
capable of providing flexibility in feed material and
product mix should be targeted.
• Planning of infrastructure to sustain further growth.
CONCLUSION:
Thank You !
M. K. DESHMUKH
DIRECTOR (E)
MECON LIMITED
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