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JSPL Patratu

13 February, 2019 PresenterV1

Agenda

1. Overview of JSPL Patratu Unit

2. Improvements & challenges -

(i) Finding solution for seam lines in wire rod specially CHQ grade and improving product quality

(ii) Controlling full decarburisation in Spring steel

(iii) Controlling GBC formation in High carbon steel

(iv) successful production of high seismic resistant TMT bar-Fe500S

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(iv) successful production of high seismic resistant TMT bar-Fe500S

13 February 2019 PresenterV1

JSPL Patratu Process Overview

WRMJSPL RAIGARH

Billets via

WR/

TMT

Cust

omer

s ac

ross

In

dia

JSPL PATRATU

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BRM

RSCJSPL ANGUL

via Rail / Road

WR/

TMT

Cust

omer

s ac

ross

In

dia

Other supporting Infra

JSPL Patratu Process Overview contd..

BRM, WRM & RSC

HFO

PRODUCER GAS

ROAD LOGISTICS

INFRA

ELECTRIFIED RAILWAY

SIDING

ELECTRICITY

IOCL DAMODAR VALLEY CORP.FINSISHED GOODS DISPATCH

FINSINSHED GOODS DISPATCH

FINISHED GOODS

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BRM, WRM & RSCGAS SIDING

CENTRAL STORES

CENTRAL UTILITIESWATER

PRODUCER GAS PLANT

PATRATU DAM (PTPS) COMPRESSED AIR, PROCESSED WATER AND

OTHER UTILITIES

STORES AND SPARES SUPPLY

OTHER SUPPORTING DEPARTMENTS: FINANCE, PURCHASE, PPC & MARKETING COORDINATION, HR & ADMIN, CIVIL, LAND, EMD

FINSINSHED GOODS DISPATCH

RAW MATERIAL

Wire Rod Mill Overview

Capacity 0.6 MTPA

Technology partners Siemens (Morgan), Fives Stein for Furnace

Type of Mill Single Strand Continuous mill with NTM and RSM

Special Features • Reducing and Sizing Mill with round-round rolling gives final ovality of 0.1mm.

• Breakdown mill for high speed roughing rolling. • Warm rolling with intermediate water cooling facility to achieve

thermo mechanical rolling. This improves quality in all alloy steels.• Ring distributor to reduce coil height and shape for better packing.

Online compactor for tight packing with straps.

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• Online compactor for tight packing with straps.

Reheating Furnace Walking Beam type furnace, 160 t/hr(cold charge)

Feed Billet Size • High reduction ratio due to bigger size of billet 165mmx165mm-this improves grain structure and ensures no internal defects in wire rods.

Highest Rolling Speed 110 m/s

Stelmore Technology 100m stelmore conveyor to control all cooling parameters for online annealed wire rods and force cooling for high carbon grades.

Product Range • Wire rods (Ranging from 5.2 mm to 22.3mm in 0.5mm increments, 23.2mm, 24mm, 25mm), Re-Bars in coil form (6mm, 8mm, 10mm, 12mm)

13 February 2019 PresenterV1

Wire Rod Product Application : Sector-wise

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Bar Mill Overview

Capacity 1 MTPA

Technology partners Siemens (Morgan), Fives Stein for Furnace

Type of Mill Single Strand Continuous mill with slit line and NTM ensuring higher surface finish

Special Features • Stands in Horizontal and vertical configuration which prevents twisting of Material.

• 230 Bar Descaler to remove the Scale and ensure surface finish.• Online Water boxes for Thermo Mechanical Treatment.• 90 m Long Cooling Bed.• High Speed Rotary Entry System 90m long.

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Source: ....

13 February 2019 PresenterV1

• High Speed Rotary Entry System 90m long.• Customized online Cut lengths ( 6-12 m )with Adjustable Gauge Beam and

Cold Shear.

Reheating Furnace Walking Beam type furnace, 160 t/hr (cold charge)

Feed Billet Size 165 x 165/ 160 x 160/ 150 x 150 x 12000 mm

Highest Rolling Speed 38 m/s

TMT Process HYQST Technology(High Yield Quenched Self Tempered Steel)

Product Range TMT of 8mm to 40mm, Angles 50x50, 60x60, 75x75 and 90X90mm, PlainRounds of 20 mm to 63 mm and RCS of 40 mm to 63 mm

Rebar Service Center Overview

Products and Capacities at Rebar Service Center

Capacity 198600 MTPA

Technology partners MEP, Italy

Type of Mill Cut & Bend and Weldmesh

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Products Capacity

Cut and Bend 60000

Weldmesh 3600

U Bend 120000

Coil Straightening 12000

Binding wire 3000 (Through Conversion Agent)

Products and Capacities at Rebar Service Center

Bar Mill and Rebar Service Center Products

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• Finding solution for seam lines in wire rod specially CHQ grade and improving product quality• Controlling full decarburization in Spring steel• Controlling GBC formation in High carbon steel• Successful production of high seismic resistant TMT bar-Fe 500S

Improvements & challenges

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Generation of seam lines in finished wire rod coils

Seam lines :- These are lines in finished coils that are visible only after acid pickling. These lines are generated when material picking up scratches in rolling lines and afterwards it gets rolled.

Sources of generation:-These lines are generated when ever material is • Getting rubbed continuously/discontinuously in rolling line.

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• Getting rubbed continuously/discontinuously in rolling line.• It is passing through a groove• Fin generated in upstream stands getting rolled.• Material rubbing against jammed rolls/chips accumulated/ any hard surface

Impact of Scratch in finished Wire rodsØApplication - These material are used in manufacturing fasteners.

ØWhile drawing and upsetting operation metal opens because of the scratch mark.

ØAlloy steel grades are soft material, so any scratch or damage is not allowed.

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Corrective actions taken:1. Maintaining stock so that fin generations at any stand is abolished.2. To find out sources of scratch generation up stream .3. To provide minimal contact with troughs when material travels.

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Looper is there in between PFM and NTM to regulate tension. It pushes the metal and support it on the bed forming a parabolic

shape.

looper bed

Material passing through looper 6

Looper

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Looper bed

Generation of seam lines

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PROBLEM

• In long course bed gets wear out and depression and sharp edges formson the bed.

• When material passes over it scratches are formed on the wire rod andafter further rolling in ahead stands seam lines are generated.

• These seam lines are not visible in black condition, only after acidpickling it comes out and wire rod is failed in upset test.

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pickling it comes out and wire rod is failed in upset test.

• Due to this we have to discard more rings at trimming station resultingin yield losses and delays.

• Even after this we face problem of coil rejection and customercomplaints.

ANALYSISOnce the problem was identified we worked on the possiblesolutions.1. Looper bed is made of cast iron, we have the option to weld

the bed and grind it to maintain the surface condition.

Results:- During shutdown in May,16 we welded the looperbed. It works fairer but welded parts once again get wear outrapidly after few days.

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2. Replace the bed with harder material so that rubbing effectis nullified.

Decision :- we decided to replace the looper bed with SS 310material.

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Most damaged portion

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SS 310 plate 1850X395 mm

Delivery Turndown pipe

Point of Pinch Roll 10º

Layout of Turndown pipe & Intelligent Pinch Roll

Entry Turndown pipePinch RollLaying

Head

Metal Entering

Metal Entering

Metal Entering

Before Modification

Entry

PIPE PIPE

DeliveryEntry Turn-Down Pipe

ASSEMBLYASSEMBLY

DeliveryTurn-Down Pipe

BASE

PIPE ASSEMBLY

• In first modification roller was placed in top position of the pipe but problem was not completelyresolved

After 1st Modification

DELIVERY TURNDOWN PIPE

ENTRY TURNDOWN PIPE

PIPE ASSEMBLY

• Groove mark was actually found in two places in pipe in ‘U’ shape.

• When pipe was cut in two halves, scratch mark was observed at bottom position also but atdifferent location. So, we decided to fix roller at bottom position also.

Observation after 1st Modification

AB

Top Groove

AB

B-B Section view of pipe with Scratch mark(When metal enters the Pipe)

BottomGroove

A-A Section view of pipe with Scratch mark(When metal enters the Laying head)

Turndown Pipe

Wire Rod

Metal enters Laying head

After 2nd Modification

ENTRY TURNDOWN PIPE

DELIVERY TURNDOWN PIPE

v Scratch marks in Finished Wire rods

Problems in Wire rods

As Rolled Coil

Acid Etching

Sample of Coil after ModificationAfter Modification – Scratch free wire rod

As Rolled Coil Acid Etching

Delay due to line coming in coil

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Customer complaints due to seam lines

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OBSERVATION

We replaced it during mill shutdown• When mill started no seam lines were observed in wire rods

and delay due to this has reduced drastically up to nil.• Rings discarded at trimming station is nominal.• Number of customer complaints regarding seam lines has

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• Number of customer complaints regarding seam lines hasreduced considerably.

• Wear out rate of replaced plate is very slow and no scratchesbeing generated.

BENEFITS

• No customer complaints is being received of upset failure, seam lines, black linesespecially in boron grade.

• Lesser rings are discarded at trimming station helping in improving yield and preventingdelay due to slow trimming.

• Improvement in mill productivity as down time due to scratches has been eliminated.

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• Handling of lesser rings at trimming station has improved safety incidences and workplace pleasure.

COST SAVING

Total delay due to this problem = 3977 min

Considering average production of 100 MT per hourTotal production in 3977 min = 6288.33 MT

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Total production in 3977 min = 6288.33 MT

Total saving in conversion cost = 6288.33X Rs 3000 = Rs 19885000

Total saving in profit realization = 6288.33 X Rs 4000 = Rs 26513333

Total saving = Rs 46398333

Tangible

Sl No. Description Disadvantages of previous design Advantages after Modifications

1 Defects in Coil

• Continuous or discontinuous scratch marks and sometimes through out the coils

• Leading to Non Prime & Rejection of Coils

• Zero Scratch• Zero Non Prime • Zero Rejections

Pipe • 1 entry & 1 delivery pipe per

Tangible & Intangible Benefits

2Pipe Consumption

• 4 Entry & 4 delivery pipes per day• 1 entry & 1 delivery pipe per

day

Intangible

3 DelayDelay in• Searching scratch in coils• Sample checking

• Zero delay

4Production Loss

• More production loss due to more delay

• Zero loss

Grade % C % Mn % S % P % Si % Al % Cr

SAE 9254 0.51-0.59 0.60-0.80 0.015 Max 0.020 Max 1.20-1.60 0.025 Max 0.60-0.80

Controlling Full decarburization in Spring Steel(SAE9254)

Application – Suspension spring in automobile industry

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Full Decarb image- Complete loss of carbon due to decarburization . It makes lesser the

surface strength/hardness

Testing – Fatigue test upto 2000000 Cycle, Requirement-Zero Full decarbTo reduce/ eliminate different combination of element al change, coating , reducing oxygen level , process parameter were used. Element addition but it will increase the cost .less Oxygen level in Furnace – It has reduced FD but not eliminated completely

Now wire rod in different sizes are being produced free from full decarburization with the help of high cooling rate.

Controlling GBC formation in High carbon steel

What is GBC –How it develops - In which grades it generally it comes and why ?

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Grain Boundary Cementite

• Effect of GBC- Burst/breakage in wire drawing, spring making or different other application .

Challenge– Still we are working on it to remove it completely

. How can we remove ? – By increasing the cooling rate significantly above eutectoid temp ?

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Any other way to minimize it ?

Successful production of high seismic resistant TMT bar-Fe 500S

Fe500S – Seismic Resistant Rebar . Challenge – Maintaining High UTS/ YS ratio 1.25 which will increase its toughness First commercial production of 3000 MT

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Fe500D Fe500S

Thank You !

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