ENGINEERS INDIA RESEARCH INSTITUTE

4/54, Roop Nagar, Delhi-110007 (India)

TMT BAR FROM SCRAP

MS Billets

The Induction furnace based on mini steel plant is a versatile installation where
provisions are available for producing a range of steel products by Alloying and
casting into various shape. The products of steel plants are in the form of Ingots,
Billets, Sheets etc. These Induction furnace-based steel casting units are suitable
for small scale industries and medium scale industries and yet have the capability
to complete in the internal as well as international market at all counts. In mini
steel plant operating under Indian conditions small Billets are Cast for rolling into
structural sections, Mild steel billets are manufacturing by different types of
furnaces such as Blast Furnace, Electric Arc furnace, Induction Furnace, Basic
oxygen furnace etc.

The available sizes of the steel billets are

• 100 x 100 mm2

Billets are the basic products of steel from which different types of steel products
are made such as sheets, Angles, Channels, Rods, etc. Mild steel Billets are the
basic raw material for manufacturing various types of re-rolled products.

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 CONTENTS

MS BILLETS 13
THE AVAILABLE SIZES OF THE STEEL BILLETS ARE 13
IMPORTANT ASPECTS OF CONTINUOUS CASTING OF BILLETS 14
TMT BARS 18
WHAT ARE TMT STEEL BARS? 19
ADVANTAGES OF TMT BARS 21
PHYSICAL PROPERTY 23
CHEMICAL PROPERTY 23
USES/APPLICATIONS 24
MS BILLETS 24
TMT BARS 24
TMT BARS FIND WIDE APPLICATIONS IN DIFFERENT SPHERES: 24
SPECIFICATIONS 25
MS BILLETS 25
TMT BARS 25
FOR MORE INFORMATION CONTACT AT: 27
FURNACE 28
THE FURNACE HAS THREE PROCESSES: - 28
FEEDING 28
HEATING CHAMBER 29
FURNACE EXIT: 29
ROUGHING MILL: 30
CUTTERS 32
INTERMEDIATE MILL: 33
FINISHING MILL 34
TMT QUENCHING BOX: 35
QUALITY CONTROL 36
CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES OF STEEL (INDIAN
STANDARD) 36
BEND TEST 41
REBEND TEST 41
WEIGHT DETAILS 41
MARKET OVERVIEW OF BILLETS AND BAR 42
MS BILLETS 42
GROWTH FACTORS OF MILD STEEL BILLET MARKET: 44
TMT BARS 45

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APPLICATION INSIGHTS: 46
REGIONAL ANALYSIS 47
GROWTH FACTORS: 47
STAGES IN TMT BAR MANUFACTURING 48
STAGE 1 – SOURCING MATERIALS AND PROCESSING 48
THE FOLLOWING PROCESSES CAN BE USED: 48
STAGE 2 – MAKING STEEL BILLETS 48
STAGE 3 – MAKING TMT REINFORCEMENT BAR (REBARS) FROM STEEL
BILLETS 49
THIS IS FINAL MANUFACTURING PROCESS THAT PRODUCES THE
TMT STEEL REBARS 49
CONVERSION OF BILLETS INTO STEEL 50
CONVERSION OF BILLETS TO STEEL: 50
THERMO MECHANICAL TREATMENT: 50
THESE THREE ESSENTIAL STEPS ARE: 51
QUENCHING: 51
SELF-TEMPERING: 51
ATMOSPHERIC COOLING: 51
MANUFACTURING PROCESS – MS BILLETS 52
PREPARATION OF SCRAP 53
PROCESSES FOR SORTING AND PREPARATION OF STEEL SCRAP 55
MECHANICAL PROCESSES 56
PROCESSES FOR PREPARATION OF STEEL SCRAP 58
MAGNETIC SEPARATION PROCESS 59
EDDY CURRENT SEPARATION PROCESS 59
HEAVY MEDIA SEPARATION PROCESS 60
SEPARATION BY PHYSICAL AND CHEMICAL CHARACTERISTICS 61
DECOATING PROCESSES 63
DEZINCING PROCESS FOR STEEL SCRAP 64
DETINNING PROCESS FOR STEEL SCRAP 66
DECOPPERIZATION PROCESS FOR STEEL SCRAP 67
INCINERATION 67
PORTABLE OPTICAL EMISSION SPECTROMETERS 68
COLOUR SORTING PROCESS 68
PROCESS UTILIZING LASER INDUCED BREAKDOWN SPECTROSCOPY 69
MELTING 70
OPERATION OF INDUCTION FURNACE 70
SCHEMATICS OF AN INDUCTION FURNACE 74

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A CORELESS INDUCTION FURNACES 75
BATH AGITATION MECHANISM 76
THE POWER DISTRIBUTION AND FLOW PATTERN IS SHOWN IN FIG 3. 76
POWER DISTRIBUTION (LEFT) AND FLOW PATTERN (RIGHT) 76
REFRACTORY LINING 77
PRODUCTION OF MILD STEEL BY INDUCTION FURNACE 78
COMPARISON WITH ELECTRIC ARC FURNACE STEEL MAKING PROCESS 78
TABLE 1 COMPARISON OF OPERATING PARAMETERS WITH ELECTRIC ARC
FURNACE (EAF) 79
KEY ADVANTAGES OF INDUCTION HEATING 80
IMPORTANT ASPECTS OF OPERATION 80
OTHER ASPECTS OF INDUCTION FURNACE STEEL MAKING 83
FIG 1 TYPICAL HEAT BALANCE DIAGRAM OF CRUCIBLE INDUCTION
FURNACE 84
ENVIRONMENTAL EMISSIONS 86
SAFETY AND INDUCTION FURNACES 88
TMT BAR 89
THE THERMO MECHANICAL TREATMENT INVOLVES 3 ESSENTIAL STEPS
THOSE ARE: 89
THE QUALITY OF TMT BAR DEPENDS ON THREE MAJOR FACTORS 89
PRIMARY STEEL MAKING 89
THERMO MECHANICAL TREATMENT 90
QUENCHING – 90
THIS COOLING TECHNOLOGY IS KNOWN AS QUENCHING. 90
SELF TEMPERING – 90
ATMOSPHERIC COOLING – 90
PROCESS FLOW DIAGRAM OF TMT BAR FROM SCRAP 91
CONTINUOUS CASTING OF STEEL BILLETS 92
SINGLE STRAND BILLET CASTER 94
EIGHT STRAND BILLET CASTING MACHINES 94
THE PROCESS OF THE CONTINUOUS CASTING OF STEEL BILLETS IS
DESCRIBED BELOW 95
STEEL LADLE 95
TUNDISH 96
MOULD 100
SECONDARY COOLING 108
TUNDISH AND ITS ROLE IN CONTINUOUS CASTING 111
A TUNDISH IN A CONTINUOUS CASTING MACHINE 112

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TUNDISH-A METALLURGICAL VESSEL 113
TUNDISH REFRACTORY LINING 115
BILLET INSPECTION AND CONDITIONING FACILITIES 118
INSPECTION TECHNIQUES 122
BILLET INSPECTION TECHNIQUES 122
EDDY CURRENT TECHNIQUES 123
FLUX LEAKAGE TECHNIQUES 124
MICROWAVE TECHNIQUES 125
OPTICAL TECHNIQUES 125
THERMAL TECHNIQUES 126
ULTRASONIC TECHNIQUES 127
SELECTION OF INSPECTION TECHNIQUES 127
BILLET CONDITIONING FACILITIES 128
ROLLING MILL - TMT 130
TYPICAL LAYOUT OF 3-DRIVE CROSS COUNTRY TYPE ROLLING MILL 130
MAJOR EQUIPMENTS/PARTS OF STANDARD CROSS COUNTRY TYPE ROLLING
MILL 130
A STANDARD CROSS COUNTRY TYPE ROLLING MILL IN THE SME-SRRM
SECTOR HAS THE FOLLOWING MAJOR EQUIPMENTS/PARTS: 131
GRADES OF INPUT MATERIAL & FORM 136
THE PROMINENT GRADES OF ALLOY STEELS BEING ROLLED INCLUDE: 136
TYPICAL MILL PRODUCT RANGE 137
STANDARD OPERATING PRACTICES IN ROLLING MILL - TMT 138
RAW MATERIAL SECTION 138
RECEIVING, TESTING & STACKING OF INGOTS/ BILLETS 138
BILLET PREPARATION 139
STANDARD OPERATING PROCEDURES FOR ROLLING MILL 140
ROLLING SUPERVISION & SECTION CONTROL 140
THE IMPORTANT ASPECTS TO BE KEPT IN MIND DURING ROLLING
SUPERVISION ARE: 140
EMERGENCY STOPPING OF MILL 143
ACTION TAKEN IN THE EVENT OF COBBLE 144
MEASURES TO BE ADOPTED FOR INCREASING MILL UTILIZATION 146
SPINDLES 148
MILL HOUSING 149
ROLLER TABLES, TILTING, Y-ROLLER TABLES 150
WALL –TILTERS 151
FRONT & BACK END CROPPING SHEARS 152

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THERMO-MECHANICAL TREATMENT OF STEEL (TMT) SYSTEM 153
COOLING BEDS 154
HYDRAULIC & PNEUMATIC SYSTEMS 155
IN THE HYDRAULIC SYSTEMS THE IMPORTANT PARAMETERS TO BE
OBSERVED ARE: 155
MILL ELECTRICS; POWER SUPPLY & DISTRIBUTION SYSTEM 156
POWER SUPPLY & DISTRIBUTION SYSTEM 157
CONTROL PANELS 159
PROCESS CONTROL/PROGRAMMABLE LOGIC CONTROL (PC/PLC) FOR
ROLLING MILLS 160
CENTRALISED OIL LUBRICATION & GREASING SYSTEM 161
CENTRALIZED OIL LUBRICATION SYSTEM (COLS) 161
CENTRALIZED GREASE LUBRICATION SYSTEMS (CGLS) 162
MILL COOLING WATER SYSTEM 164
MANUFACTURING PROCESS/PROCESS FLOW – TMT BAR 166
RAW MATERIAL SUPPLIERS 167
SUPPLIERS OF STEEL SCRAP 167
SUPPLIERS OF PLANT AND EQUIPMENTS 168
CONCASTING MACHINE 168
INDUCTION FURNACE 171
METAL TESTING MACHINE 172
PRECISION MEASURING TOOLS 173
NDT INSPECTION EQUIPMENT 174
ELECTRICAL MEASURING INSTRUMENTS 175
EOT CRANES 176
ELECTRICAL PANEL 180
COOLING TOWER 182
ROLLING MILL 185
SHAPING MACHINE 186
SUPPLIERS OF INDUCTION FURNACE 187
SHEARING MACHINE 188
DRILLING MACHINE 189
LATHE MACHINE 190
GRINDING MACHINE 191
ARC WELDING MACHINE 191
POWER TRANSFORMERS 192
SUPPLIERS OF ETP PLANTS 194
CRUSHING PLANT 195

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BALL MILL 196
ELECTRICAL PANEL 197
AIR CONDITIONING EQUIPMENTS 198
AIR COMPRESSOR 199
PLATFORM WEIGHING MACHINE 200
MATERIAL HANDLING EQUIPMENTS 201
FIRE FIGHTING EQUIPMENTS 202
HDPE BAGS 203
MATERIAL HANDLING EQUIPMENTS 204
UTILITIES REQUIREMENT (ESTIMATED - MONTH) 206
ENGINEERING DESIGN CONSIDERATIONS 207
ETP FACILITY 208
ETP FLOW DIAGRAM (TYPICAL) 209
SEWAGE AND WASTE WATER EFFLUENT 211
STP FLOW DIAGRAM (TYPICAL) 212
WASTE GENERATION & MANAGEMENT / GREEN BELT 213
GREEN BELT 213
WATER (ESTIMATED) 213
WASTE (ESTIMATED) 214
FLUE GAS (ESTIMATED) 214
PRINCIPLES OF PLANT LAYOUT 215
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE
SERVICE ARE: 220
PLANT LOCATION FACTORS 221
PRIMARY FACTORS 221
RAW-MATERIAL SUPPLY: 221
MARKETS: 221
POWER AND FUEL SUPPLY: 221
WATER SUPPLY: 222
CLIMATE: 222
TRANSPORTATION: 222
WASTE DISPOSAL: 222
LABOR: 222
REGULATORY LAWS: 223
TAXES: 223
SITE CHARACTERISTICS: 223
COMMUNITY FACTORS: 224
FLOOD AND FIRE CONTROL: 224

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ANTICIPATED ENVIRONMENTAL IMPACTS 225
CONSTRUCTION PHASE 225
OPERATION PHASE 225
MITIGATION MEASURES (PROPOSED) 226
HEALTH SAFETY & ENVIRONMENT 227
PROPOSED IMPLEMENTATION SCHEDULE 228
PROJECT FINANCIALS 229
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS) 229

APPENDIX – A:
01. PLANT ECONOMICS A-1
02. LAND & BUILDING A-2
03. PLANT AND MACHINERY A-3
04. OTHER FIXED ASSESTS A-4
05. FIXED CAPITAL A-5
06. RAW MATERIAL A-6
07. SALARY AND WAGES A-7
08. UTILITIES AND OVERHEADS A-8
09. TOTAL WORKING CAPITAL A-9
10. TOTAL CAPITAL INVESTMENT A-10
11. COST OF PRODUCTION A-11
12. TURN OVER/ANNUM A-12
13. BREAK EVEN POINT A-13
14. RESOURCES FOR FINANCE A-14
15. INSTALMENT PAYABLE IN 5 YEARS A-15
16. DEPRECIATION CHART FOR 5 YEARS A-16
17. PROFIT ANALYSIS FOR 5 YEARS A-17
18. PROJECTED BALANCE SHEET FOR (5 YEARS) A-18

COST ESTIMATION
Plant Capacity 300 MT/Day
Land & Building (16,000 sq.mt.) Rs. 8.70 Cr
Plant & Machinery Rs. 20.90 Cr
Working Capital for 1 Month Rs. 28.40 Cr
Total Capital Investment Rs. 59.31 Cr
Rate of Return 45%
Break Even Point 56%

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