Steel Plant Tech Latest

37
1 MECON LIMITED MECON LIMITED MECON LIMITED MECON LIMITED TECHNOLOGICAL DEVELOPMENT & PROFITABILITY IN STEEL INDUSTRIES

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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