1

PROJECT REPORT

(Project Semester January-May 2014)

ANALYSIS OF MANUFACTURING PROCESSES IN SMALL

AND MEDIUM SIZE ENTERPRISE OF STEEL PRODUCTS

SUCH AS STRUCTURE ANGLES, FLAT BARS, PLAIN RODS

ETC. WITH THEIR APPLICATIONS AND MARKET

DEMAND

Submitted by

Deepankar Jain

Registration No- 11008858

Under the Guidance of

Faculty coordinator: Mr. Prashant Bagde Industry coordinator: Mr. Samir Paul

Designation: Internal Training Supervisor, Designation: HOD of Training,

LPU, Jalandhar, Punjab Assam Tubes Limited,

Guwahati, Assam

Department of Mechanical Engineering

School of Mechanical Engineering

Lovely Professional University, Phagwara

Jan-May 2014

2

CONTENTS

1. COMPANY PROFILE 9

a. OVERVIEW 9

b. COMPANY VISION 9

c. COMPANY’S QUALITY 10

d. PRODUCTS 10

2. INTRODUCTION 11

a. STRUCTURAL STEEL 11

b. ADVANTAGES OF STRUCTURE STEEL 11

c. DISADVANTAGES OF STRUCTURE STEEL 12

3. COMPANY’S MANUFACTURING DEPARTMENT 13

a. INTRODUCTION 13

b. FURNACE 13

i. INDUCTION FURNACE 14

ii. REHEAT FURNACE 14

c. MACHINERY 14

i. ROLLING MILLS 14

ii. LATHE MACHINES 14

iii. ARC WELDING MACHINES 14

iv. METAL SHEARING UNIT 14

d. MATERIAL HANDLING SYSTEM 14

i. ROLLERS 15

ii. EOT CRANES 15

iii. INGOTS MOULDS 16

4. MANUFACTURING PROCESSES 16

a. RAW MATERIALS REQUIRED 16

i. SCRAPS 16

ii. SPONGE IRON 16

iii. ALUMINIUM 17

iv. SILICO MANGENESE 17

v. CARBON COKE 17

b. OTHER REQUIREMENTS 18

i. COAL 18

ii. RAMMING MASS 18

c. MANUFACTURING UNIT FLOWs DIAGRAM 19

d. MORE DETAILS OF ASSAM TUBES LIMITED MANUFACTURING

UNIT 20

5. MANUFACTURING OF INGOTS 21

a. DEFINITION OF INGOTS 21

b. WHY INGOTS ARE MANUFACTURED? 21

c. COMPOSITION OF RAW MATERIALS 21

3

d. CONTRIBUTION OF RAW MATERIALS 22

i. SCRAP AND CAST IRON 22

ii. SPONGE IRON 22

iii. FERROMANGENESE 22

iv. SILLICA MANGENESE 22

v. ALUMINIUM WIRES 22

vi. COKE 22

e. OVERALL COST OF RAW MATERIAL 23

f. DESCRIPTION OF PROCESS 23

g. PICTURES OF MANUFACTURING UNIT REGARDING INGOTS

MANUFACTURING 25

h. INGOTS MOULDS 26

i. INGOT DEFECTS 26

i. PIPE FORMATION 26

ii. BLOW HOLES 27

iii. NON METALLIC INCLUSIONS 27

iv. INGOT CRACKS 28

6. MANUFACTURING OF PRODUCTS 29

a. REHEAT AND BULK DEFORMATION 29

b. PICTURES OF MANUFACTURING UNIT REGARDING REHEAT AND

BULK DEFORMATION 30

7. DETAILS OF FINAL PRODUCTS MANUFACTURED 32

8. OTHER COMPLIMENTARY DEPARTMENTS TO MANUFACTURING UNIT 34

a. LATHE MACHINING UNIT 34

b. POWDERED COAL STORAGE UNIT 35

c. INGOT’S MOLD MANUFACTURING UNIT 35

9. TIME FACTOR ANALYSIS FOR PRODUCTION OF INGOTS 36

a. FOR EOT(ELECTROMAGNETIC) 36

b. FOR INDUCTION FURNACE 36

c. FOR CASTING 36

d. FOR EOT(MULTIPLE HOISTS) 36

e. IDEAL TIME CALCULATION FOR EOT(ELECTROMAGNETIC),

INDUCTION FURNACE, EOT (MULTIPLE HOISTS) 37

f. DAILY PRODUCTION OF INGOTS 37

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g. INGOTS PRODUCTION ANALYSIS PER MOULD 37

h. FOR POLISHING OF INGOTS 38

i. NUMBER OF PERSONS AT DIFFERENT STATIONS 38

10. TIME FACTOR ANALYSIS FOR REHEAT AND BULK DEFORMATION 39

a. FOR REHEAT FURNACE 39

b. FOR 3 HIGH SIX STAND ROLLING MILL 39

c. FOR SHEARING UNIT 39

d. NUMBER OF PERSONS REQUIRED AT DIFFERENT STATIONS 40

11. CALCULATION REGARDING PRODUCTION OF STEEL 41

12. CHALLENGES FACED AND MEASURES TAKEN BY THE ORGANIZATION

IN MANUFACTURING DEPARTMENT 43

a. LABOURS 43

i. HIGH LABOUR DEPENDENCY 43

ii. LACK OF SKILLED LABOUR 44

b. POWER SUPPLY 44

c. RAW MATERIAL 45

d. WEAR AND TEAR OF ROLLERS 45

e. COAL FEEDING TO THE REHEAT FURNACE 45

f. SERVICE AND MAINTAINENCE COST 45

13. THREATS 46

a. MARKET FLUCTUATION 46

b. COMPETITORS 46

c. POLITICAL AND SOCIAL ISSUES 48

d. LOW INTEGRATED INDUSTRIES 48

14. OPPURTUNITIES 49

a. HUGE INFRASTRUCTURE DEMAND 49

b. AVAILABILITY 49

c. OUTSOURCING TO OTHER COUNTRIES 49

d. ONLINE BUSSINESS 49

15. FUTURE PLANS 50

16. BIBLIOGRAPHY 51

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LIST OF FIGURES

FIG NO. DESCRIPTION PAGE

NO.

FIG1 ASSAM TUBES LIMITED 9

FIG2 DIFFRENT STEEL STRUCTURE PRODUCTS

MANUFACTURED BY THE COMPANY

10

FIG3 ROLLING MILL AT ASSAM TUBES LIMITED 14

FIG4 CAST IRON 16

FIG5 SPONGE IRON 16

FIG6 INDUCTION FURNACE AND RAW

MATERIALS

18

FIG7 INGOTS AT INGOT STORAGE UNIT AT

ASSAM TUBES LIMITED

21

FIG8 (A) SILLICA MANGENESE (B) FERRO

MANGENESE (C) ALUMINIUM WIRES

22

FIG9 EOT with electromagnet lifting scrap and cast iron. 25

FIG10 AT THE TOP TABLE OF INDUCTION

FURNACE

25

FIG11 CONTROL ROOM FOR THE INDUCTION

FURNACE

25

FIG12 MOULD FOR CASTING OF INGOTS 25

FIG13 COMBINED PICTURE OF MELTING AND

CASTING UNIT

25

FIG14 INGOTS STORED AT INGOTS STORAGE FOR

FURTHER PROCESSING

25

FIG15 FINAL POLISHING OF INGOTS WITH

GRAPHITE FOR BETTER FINISHING OF

FINISHED PRODUCTS

25

FIG16 NARROW END UP MOULD FOR INGOT

CASTING

26

FIG17.1 NARROW END UP MOULD SHOWING LONG

PIPE IN KILLED STEEL

27

FIG17.2 RIMMING AND SEMI-FINISHED STEEL SHOW 27

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VERY LESS TENDENCY FOR PIPE

FORMATION

FIG18 PRIMARY ROLL FOR STRUCTURAL SHAPES.

29

FIG19 SIDE VIEW OF REHEAT FURNACE 30

FIG20 INGOTS FED INTO REHEAT FURNACE OF

TEMPERATURE TREATMENT

30

FIG21 PILED UP POWDERED COAL ACTING AS

FUEL FOR REHEAT FURNANCE

30

FIG22 BUCKET ELEVATOR, HOOPER AND FEEDER

ARRANGEMENT FOR TRANSPOTING COAL

TO REHEAT FURNACE

30

FIG23 SKILLED LABOURS TRANPORTING HEATED

INGOTS TO THE ROLLING MILL

31

FIG24 SKILLED LABOURS WORKING AT REHEAT

FURNACE UNIT

31

FIG25 SIX ATND STANDING ROLLERS 31

FIG26 DIFFERENT ROLLERS USED

MANUFACTURING DIFFERENT PRODUCTS

31

FIG27.(A) USED ROLLERS FROM ROLLING MILLS

WHICH WILL UNDERGO MACHINING

34

FIG27.(B) ROLLERS AFTER MACHININHG FOR REUSE 34

FIG27.(C) GROOVING IS PERFORMED ON A ROLLER

OVER LATHE MACHINE

34

FIG27.(D) PICTURE OF A ROLLER FITTED BETWEEN

LATHE CHUCK AND TAIL STOCK.

34

7

LIST OF TABLES

TABLE

NO.

DESCRIPTION PAGE

NO.

TABLE1 TABULATED FORM OF MANUFACTURING

FURNACE, MACHINERY AND MATERIAL

HANDLING SYSTEM DETAILS

15

TABLE2 SPONGE IRON COMPOSITION 16

TABLE3 TABULATED FORM OF RAW MATERIALS

PROCUREMENT, USAGE, COMPOSITION

AND COST

17

TABLE4 COMPOSITION OF RAW MATERIAL 21

TABLE5 TOATAL COST OF RAW MATERIAL 23

TABLE6 FURNACE DETAILS 24

TABLE7 DAILY PRODUCTION 28

TABLE8 PRODUCTS AVAILABLE STOCK DETAIL 32

TABLE9 PERSON REQUIREMENT AT INGOT

MANUFACTURING UNIT

38

TABLE10 PERSON REQUIREMENT AT REHEAT AND

BULK DEFORMATION UNIT

40

TABLE11 TABULATED FORM OF PRODUCED

LENGTH

41

TABLE12 RATE OF PRODUCTION 42

TABLE13 APPROXIMATE PEOPLE REQUIREMENT AT

DIFFERENT WORKSTATIONS

43

TABLE14 COMPANY’S LONG AND SHORT TERM

PLANS

50

PREQUISITE KNOWLEDGE

1. DUCTILITY 5. MOULDS

2. BUCKLING 6.HOT ROLLING PROCESS

3. ROLLING MILLS 7. ROLLERS

4. LATHE MACHINES 8. WELDING MACHINES

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ACKNOWLEDGEMENT

I am grateful to my college ‘Lovely Professional University’ for giving me this opportunity

to work as a trainee in an organization which gave a profound practical experience of what

theoretical knowledge I have gained during my college period. I am immensely grateful to all

the concerned staff respective of their work area inside the organization’s campus whose

guidance and co operations was beneficial and made the training worth learning. My sincere

thanks to:

Mr. Gowardhan Royal Human Resource Department

Mr. Ashok Kumar Manufacturing Department

Mr. Pritambar Kumar Sales and Marketing Department

Mr. Samir Paul Training Department

I would also like to thank Mr. Prashant Bagde as my training supervisor assigned by the

university, who was immensely helpful and supportive throughout my training period.

9

5.

FIG1: ASSAM TUBES LIMITED

1. COMPANY PROFILE

1. a. OVERVIEW- Established in 1962, Assam tubes Ltd is among the top ten steel

companies in North East with an annual steel capacity of 72000 tons per annum (Mtpa). It is

now one of the most geographically-diversified steel producers, with operations in the seven

sister states of North Eastern Region along with Bhutan, Bangladesh and Myanmar.

Assam Tubes Ltd. with a turnover of Rs.115.70 Crs in Financial Year 2011-2012, has over

250 employees. The company’s vision is to achieve maximum product mix in the steel

manufacturing industry through the excellence of its people, its innovative approach and

overall conduct. The structural steel products being manufactured are widely accepted in

highly discerning consumer sectors such as construction, automotive, infrastructure,

engineering, telecom, white goods etc.The Company enjoys a network of a large number of

reliable dealers since last 30 years.

1. b. COMAPNY’S VISION- Assam Tubes Ltd. is dedicated to safely produce the best

quality structural steel products for the customers, delivering them on-time and providing

them with outstanding service. Assam Tubes Ltd. is committed to being a responsible

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corporate citizen. It is our intention to operate ethically with all constituents, maintaining fair

and honest relationships and to operate within both the letter and the spirit of the law. From

the shop floors of all of our plants to the executive offices, Assam Tubes Ltd. is devoted to

achieving excellence in all we do on behalf of each stakeholder every day.

1. c. COMPANY’S QUALITY- Assam Tubes team is dedicated to being the leader in safely

producing superior products with pride and integrity with management commitment to

continually improve the effectiveness of the quality management system. We are committed

to increasing profitability through mutually beneficial relationships with our employees,

customers and suppliers. Assam Tubes Ltd. shall seek to achieve excellence in safety, quality

and productivity through the selection and monitoring of key indicators.

1. d. PRODUCTS-

FIG 2: DIFFRENT STEEL STRUCTURE PRODUCTS MANUFACTURED BY THE

COMPANY

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2. INTRODUCTION

2. a. STRUCTURE STEEL- Structural steel is steel construction material, a profile, formed

with a specific shape or section and certain standards of chemical composition and

mechanical properties. Structural steel shape, size, composition, strength, storage, etc., is

regulated in most industrialized countries.

2. b. ADVANTAGES OF STRUCTURE STEEL-

I. High strength/weight ratio. Steel has a high strength/weight ratio. Thus, the dead

weight of steel structures is relatively small. This property makes steel a very

attractive structural material for

a. High-rise buildings

b. Long-span bridges

c. Structures located on soft ground

d. Structures located in highly seismic areas where forces acting on the structure due

to an earthquake are in general proportional to the weight of the structure.

II. Ductility. As discussed in the previous section, steel can undergo large plastic

deformation before failure, thus providing a large reserve strength. This property is

referred to as ductility. Properly designed steel structures can have high ductility,

which is an important characteristic for resisting shock loading such as blasts or

earthquakes. A ductile structure has energy-absorbing capacity and will not incur

sudden failure. It usually shows large visible deflections before failure or collapse.

III. Predictable material properties. Properties of steel can be predicted with a high

degree of certainty. Steel in fact shows elastic behaviour up to a relatively high and

usually well-defined stress level. Also, in contrast to reinforced concrete, steel

properties do not change considerably with time.

IV. Speed of erection. Steel structures can be erected quite rapidly. This normally results

in quicker economic payoff.

V. Quality of construction. Steel structures can be built with high-quality workmanship

and narrow tolerances.

VI. Ease of repair. Steel structures in general can be repaired quickly and easily.

VII. Adaptation of prefabrication. Steel is highly suitable for prefabrication and mass

production.

VIII. Repetitive use. Steel can be reused after a structure is disassembled.

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IX. Expanding existing structures. Steel buildings can be easily expanded by adding

new bays or wings. Steel bridges may be widened.

X. Fatigue strength. Steel structures have relatively good fatigue strength.

2. c. DISADVANTAGES OF STRUCTURE STEEL-

I. General cost. Steel structures may be more costly than other types of structures.

II. Fireproofing. The strength of steel is reduced substantially when heated at

temperatures commonly observed in building fires. Also, steel conducts and transmits

heat from a burning portion of the building quite fast. Consequently, steel frames in

buildings must have adequate fireproofing.

III. Maintenance. Steel structures exposed to air and water, such as bridges, are

susceptible to corrosion and should be painted regularly. Application of weathering

and corrosion-resistant steels may eliminate this problem.

IV. Susceptibility to buckling. Due to high strength/weight ratio, steel compression

members are in general more slender and consequently more susceptible to buckling

than, say, reinforced concrete compression members. As a result, considerable

materials may have to be used just to improve the buckling resistance of slender steel

compression members.

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3. COMPANY’S MANUFACTURING DEPARTMENT

3. a. INTRODUCTION- The Manufacturing Department is the heart of the industry

supervised by Mr. Ashok Kumar. The department controls the manufacturing processes from

the raw materials procurement to the finished product transportation to storage cell. More

than 85% of the human workforce is contributing to this department. The manufacturing

department is responsible for the functioning and periodic maintenance of the machineries.

The department is working on the principle of batch size production. The manufacturing unit

compromises of furnace, machineries, material handling system, electric motors etc.which

will be discussed in the following section.

3. b. FURNACE-

i. INDUCTION FURNACE- An induction furnace is an electrical furnace in which

the heat is applied by induction heating of metal. The advantage of the induction

furnace is a clean, energy-efficient and well-controllable melting process compared to

most other means of metal melting. The greatest advantage of the Induction Furnace

is its low capital cost compared with other types of Melting Units. Its installation is

relatively easier and its operation simpler. Among other advantages, there is very little

heat loss from the furnace as the bath is constantly covered and there is practically no

noise during its operation. The molten metal in an Induction Furnace is circulated

automatically by electromagnetic action so that when alloy additions are made, a

homogeneous product is ensured in minimum time. The time between tap and charge,

the charging time, power delays etc. are items of utmost importance are meeting the

objective of maximum output in tones/hour at a low operational cost. An induction

furnace is highly sophisticated equipment consisting of a crucible with a lid. Heat is

generated by the induction of medium frequency electricity. The furnace is equipped

with the necessary control panel, which receives electrical power at normal 50Hz

frequency and converts the same to DC power. The DC power generated is again

converted to AC power of medium frequency, which induces the heating effect to the

furnace. In addition to the control panel, the entire furnace system is thoroughly

cooled for protection. A separate water supply system along with cooling tower is

installed to feed the furnace continuously with demineralised cool water. The furnace

can also be titled to pour out the molten metal. The inside surface of the crucible is

normally coated with castable ceramics and fire clay in intervals of the crucible is

14

normally coated with castable ceramics and fire clay in intervals of 7 days. This

practice protects the crucible and gives a longer life to the furnace.

ii. REHEAT FURNANCE- Reheating Furnace is the heart of any hot rolling mill where

in the charge is heated to rolling temperature. The charge could be in the form of

billets, blooms, slabs or ingots. The type of furnace could be pusher, walking hearth

or walking beam – either top fired or top and bottom fired. The fuel used could be

either oil or gas. The burners are located in a manner so as to achieve uniform heat

distribution. The radiation heat energy is efficiently transferred through the useful

heat transfer area created by the charge bed. The furnace is basically divided into

three zones namely preheating, heating and soaking zones. The actual heating takes

place in the heating zone. The temperature uniformity up to desired limits between the

core and the surface is achieved in the soaking zone. The flue gases move in a

direction opposite to that of the charge thereby ensuring considerable amount of waste

heat recovery by convection in the preheating zone, which is also termed as the

recuperative zone.

3. c. MACHINERY-

i. ROLLING MILLS- 3-HIGH SIX STAND ROLLING MILL, 5 STAND

TANDENEM ROLLING MILL

ii. LATHE MACHINES

iii. ARC WELDING MACHINES

iv. METAL SHEARING UNIT

FIG3:5 STAND TANDENEM ROLLING MILL AT ASSAM TUBES LIMITED

3. d. MATERIAL HANDLING SYSTEM

i. ROLLERS

ii. EOT CRANES (ELECTRONIC OVERHEAD CRANE) - An overhead crane,

commonly called a bridge crane, is a type of crane found in industrial environments.

15

An overhead crane consists of parallel runways with a travelling bridge spanning the

gap. A hoist, the lifting component of a crane, travels along the bridge. This is most

common type of overhead crane, found in most factories. As obvious from name,

these cranes are electrically operated by a control pendant, radio/IR remote pendant or

from an operator cabin attached with the crane itself.

iii. INGOTS MOULDS

TABLE1: TABULATED FORM OF MANUFACTURING FURNACE, MACHINERY

AND MATERIAL HANDLING SYSTEM DETAILS

FURNACE MACHINERY MATERIAL HANDLING SYSTEM

INDUCT

ION

FURNAC

E

REHEA

T

FURNA

CE

SIX

STAND

S

ROLLIN

G

MILLS

LATH

E

MAC

HINE

TANDE

NEM

FIVE

SERIES

ROLLE

RS

WELD

ING

MACH

INE

ROLLERS

BED

EOT

CRANES

INGO

TS

MOU

LDS

SHEARI

NG

UNIT

TYPE

COPPER

COILED,

HYDRA

ULIC

BASED

COAL

FIRED

SECTIO

N MILL

(SIMP

LE) V

BELT

ELEC

TRIC

ARC

WELD

ING

WITH

HOIST AND

ELECTROM

MAGNET

UNIF

ORM

VARI

NG

CROS

S

SECTI

ON

AREA

HYDRA

ULIC

FLEXIB

LE

SHEARI

NG

TOOL

QUANTIT

Y TWO ONE

ONE

UNIT

WITH

FLEXIB

LE

ROLLE

RS

FIVE TWO FOUR THREE TWO

CAPACIT

Y

70

TONNES

/ DAY

10 TONNES

WEIGHT

POWER

CONSUM

PTION

800KW

DEPN

DENT

ON

COAL

SUPPL

Y

33KW

200 HP

ELEC.

MOTOR

500 HP

ELEC.

MOTOR

EACH

USES

MELTIN

G OF

SCRAPS,

CAST

IRON

FOR

PRODUC

TION OF

INGOTS

TO

SOFTE

N THE

INGOT

S FOR

ROLLI

NG

PROCE

SS

FINAL

PRODU

CTS

SHAPE

AND

SIZE

ARE

PERFOR

MED

HERE

TO

REMO

VE

BUE

FROM

THE

ROLL

ERS

AT

THE

ROLLI

NG

MILL

S

TO

FLATE

N

ANGLE

FOR

MAKIN

G

STEEL

STRIPS

GENE

RAL

WELD

ING

PURP

OSE

TRANSER

MATERIA

L FROM

ROLLING

UNIT TO

SHEARING

UNIT,

ALSO

TRANSFER

INGOTS

TO

REHEATF

URNA

HADLING

OF SCRAPS,

INGOTS

AND

INGOTS

MOULDS

USE

FOR

CASTI

NG

INGO

TS

FOR

MAKIN

G

STAND

ARD 12'

FINISH

ED

PRODU

CT

16

4. MANUFACTURING PROCESSES

4. a. RAW MATERIALS REQUIRED-

i. SCRAPS- It forms the major constituents for the production of ingots. The recyclable

material is easily available in north eastern region of India and the company purchase

from local dealers. Due to no iron ore resources near Assam and high transportation

cost, production of ingots (semi finished product) is viable and economical from scrap

iron. 80% of constituent poured in the arc furnace consist of scrap iron. Scrap

generally comes in two main grades: shred (whitegoods, cars and other objects made

of similar light-gauge steel) and heavy melt (large slabs and beams).

FIG4: CAST IRON FIG5: SPONGE IRON

ii. SPONGE IRON- Direct-reduced iron (DRI), also called sponge iron, is produced

from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing

gas produced from natural gas or coal. The reducing gas is a mixture, the majority of

which is hydrogen (H2) and carbon monoxide (CO) which act as reducing agents. This

process of reducing the iron ore in solid form by reducing gases is called direct

reduction. Sponge iron contributes 10% of the constituent for the production of

ingots. Metals that have a poorer affinity for oxygen than iron, such

as nickel and copper, cannot be removed through oxidation and must be controlled

through scrap chemistry alone, such as introducing the direct reduced iron. Assam

Tubes limited procure sponge iron from TATA Sponge Iron Limited. Orissa.

TABLE2: SPONGE IRON COMPOSITION

Product Name Specifications

Sponge Iron - Fe (M) - 80 % Min

- Fe (T) - 90-92 % Min

- C - 0.09 % Min

- S - 0.045 % Max

17

iii. ALUMINIUM- It is used for improving the physical quality of the ingots such as

strength, ductility etc. A very small amount is used as a constituent.

iv. SILICO MANGENESE-Silicomanganese (SiMn), a ferroalloy with high contents

of manganese and silicon, is made by heating a mixture of the oxides manganese

oxide (MnO2), silicon dioxide (SiO2), and iron oxide(Fe2O3), with carbon in a furnace.

They undergo a thermal decomposition reaction. It is used as a deoxidizer and an

alloying element in steel.

v. CARBON COKE- It acts as a reducing agent and mainly reduces the impurities

oxides and releasing as CO2 gas.

TABLE3: TABULATED FORM OF RAW MATERIALS PROCUREMENT, USAGE

COMPOSITION AND COST

SR.

NO.

NAME OF RAW

MATERIAL

AREA OF

PROCUREMENT

USE AS RAW

MATERIAL

COMPOSITION

COST

(INCLUDING

RAW

MATERIAL

AND

TRANSPORT)

1 SCRAP IRON LOCAL AREAS MAJOR

CONSTITUENT 85%

RS. 26500/KG

TONNES

2 SPONGE IRON TATA SPONGE IRON

LTD., ORISSA

REMOVAL OF

COPPER AND

NICKEL, MAINTAIN

PROPORTIONATE

IRON CONTETNT

10% RS.20000/ KG

TONNES

3 ALUMINIUM LOCAL

DISTRIBUTORS

QUALITY

IMPROVEMENT <0.4% APPROX. RS. 100/KG

4 SILICO

MANGENESE

SHIVAM GROUP,

KOLKATTA DE-OXIDIZER <2% APPROX. RS.65/KG

5 CARBON COKE

APCL & ICL,

NOONMATI,

GUWAHATI ASSAM

REDUCING AGENT,

CARBON CONTENT

IN STEEL

2.5%-3% RS.14/KG

18

4. b. OTHER MATERIAL REQUIREMENTS- Apart from the raw materials required for

production the manufacturing department also some other materials during the process such

as ramming mass and coal.

i. RAMMING MASS- It is used as refractory material in the induction furnace. It

prevents the copper coil wounded around the furnace to get melt. It also neutralizes

the magnetizing effect produced by the current through copper coil. Mainly silica

powder is used as ramming material.

ii. COAL- It is used as fuel in the furnace for temperature gain. It is mainly procured

from Meghalaya through local distributors. Coal powder is fed into the reheat furnace

by proper installation of bucket elevator, hooper and feeder.

Carbon Coke Sponge Iron Scrap & Cast iron Silico- manganese Aluminium & Ramming mass

FIG6: INDUCTION FURNACE AND RAW MATERIALS

19

4. c. MANUFACTURING UNIT FLOW DIAGRAM-

SCRA

INGOTS

COOLING AND

STORAGE

R

O

L

L

E

R

SHEARING UNIT

SC

RA

PA

ND

CA

ST

IR

ON

ST

OR

AG

E

IND

UC

TIO

N F

UR

NA

CE

R

O

L

L

E

R

S

LA

TH

E M

AC

HIN

E

UN

IT

POWDERED

COAL

STORAGE

REHEAT

FURNACE

3 HIGH SIX

STAND ROLLING

MILLS

ING

OT

S C

AS

TIN

G

S

TO

RA

GE

OF

FIN

ISH

ED

PR

OD

UC

TS

TANDENEM

ROLLERS FOR

ANGLE FLATENING

R

O

L

L

E

INGOT

SHEARI

NG

UNIT

INGOT

POLISHI

NG UNIT

20

4. d. MORE DETAILS OF ASSAM TUBES LIMITED MANUFACTURING UNIT-

• Material transportation from scrap and cast iron storage to induction furnace is

through electromagnetic EOT.

• There is a domestic transformer installed at the Induction Furnace station for higher

power supply.

• Molten metal from the induction furnace is poured to the ingots moulds by tilting

through hydraulic force.

• The ingots are transported to the ingots storage unit with the help of EOT having

multiple hoists.

• Before supplying ingots to the reheat furnace the ingots are first sheared into two

halves and stacked together aside for better heat distribution.

• Powdered coal storage unit is fitted with bucket elevator, hooper, feeder and conveyor

for feeding coal into reheat furnace from bottom.

• Lathe machine unit is installed for removing BUE from the rollers surface and make it

available for reuse.

• The rollers as well as the ingots cooling unit are fitted with motor driven fans of 10hp

for convection cooling.

• The temperature of the induction furnace is higher than the melting point of steel and

the temperature of the reheat furnace is lower than the melting point of steel.

21

5. MANUFACTURING OF INGOTS -

a. DEFINITION OF INGOTS- An ingot is a material, usually metal, that

is cast into a shape suitable for further processing. Non-metallic and

semiconductor materials prepared in bulk form may also be referred to as ingots,

particularly when cast by mould based methods.

FIG7: INGOTS AT INGOT STORAGE UNIT AT ASSAM TUBES LIMITED

b. WHY INGOTS ARE MANUFACTURED- The ingots are temperature treated

in a reheat furnace below its melting point to soften and by bulk deformation

rolling process the required finished product is achieved.

c. COMPOSITION OF RAW MATERIALS-

TABLE4: COMPOSITION OF RAW MATERIAL

Sr.

No.

Raw Material %Composition

1 Scrap or cast iron 85%

2 Sponge iron 10%

3 Ferro manganese <.8%

4 Silica manganese <.8%

5 Aluminium wires <.4%

6 Coke 4-5% approx.

22

d. CONTRIBUTION OF RAW MATERIALS

i. SCRAP OR CAST IRON- Apart being the major constituent of the

ingots, it’s one of the cheapest of the raw materials available for steel

structure production in North Eastern States of India. Scraps can be easily

procured from local dealer. Current market price is about Rs. 26 per kg.

Though it contains impurities such as metal oxides, dust etc, due to its

surplus availability and cost effectiveness, scraps are still preferred over

iron ore in the organization.

ii. SPONGE IRON- Metals that have a poorer affinity for oxygen than iron,

such as nickel and copper, cannot be removed through oxidation and must

be controlled through scrap chemistry alone, such as introducing the direct

reduced iron. Assam Tubes limited procure sponge iron from TATA

Sponge Iron Limited. Orissa. It is available at market price of Rs. 20 per

kg.

iii. FERRO MANGENESE- It is added for better strength to the ingots.

iv. SILICA MANGENESE- It is used as a deoxidizer and alloying element

to steel. Its market price is around Rs. 65 per kg.

(A) (B) (C)

FIG8: (A) SILLICA MANGENESE (B) FERRO MANGENESE

(C) ALUMINIUM WIRES

v. ALUMINIUM WIRES- Aluminium wires serves as a source of

aluminium which provides good surface finish and addition of quality

improvement. Very little amount of aluminium wires are mixed with other

raw materials. It is available at a market price of about Rs.100-Rs. 110 per

kg.

vi. COKE- It serves as reducing agent to remove metal oxides and releases in

the form of CO2 gas and addition of carbon contents for the formation of

steel. These are coal cokes procured directly from coking unit such as

23

APCL (Assam Petro-Chemical Limited) or ICL (India Coal Limited) at

market price of about Rs.14 per kg.

e. OVERALL COST OF RAW MATERIAL-

TABLE5: TOATAL COST OF RAW MATERIAL

For 100 kgs of ingot:

Raw material Required per 100

kgs

Amount per kg Total amount

Scraps 85 kgs Rs. 26 Rs. 2210

Sponge iron 10 kgs Rs. 20 Rs. 200

Aluminium 0.4 kgs Rs. 100 Rs. 40

Ferromanganese 0.8 kgs Rs. 80 Rs. 64

Silica manganese 0.8 kgs Rs. 65 Rs.52

Carbon coke 3 kgs Rs. 14 Rs. 42

TOTAL 100 Rs. 2608

f. DESCRIPTION OF PROCESS-For design of structures, the structural engineer

uses long and flat products. The long products include: angles; channels;

joists/beams; bars and rods; while the flat products comprise: plates; hot rolled

coils (HRC) or cold rolled coils (CRC)/sheets in as annealed or galvanised

condition. The starting material for the finished products is as given below:

i. Blooms in case of larger diameter/cross-section long products

ii. Billets in case of smaller diameter/cross-section long products

iii. Slabs for hot rolled coils/sheets

iv. Hot rolled coils in case of cold rolled coils/sheets

v. Hot/Cold rolled coils/sheets for cold formed sections.

The production process depends upon whether the input material to the steel

plant is steel scrap or the basic raw materials i.e. iron ore. In case of former,

the liquid steel is produced in Electric Arc Furnace (EAF) or Induction

Furnace (IF) and cast into ingots or continuously cast into blooms/billets/slabs

for further rolling into desired product. The steel mills employing this process

route are generally called as mini or midi steel plants. Since liquid steel after

melting contains impurities like sulphur and phosphorus beyond desirable

24

limits and no refining is generally possible in induction furnace. The structural

steel produced through this process is inferior in quality.

The organization ‘ASSAM TUBES LIMITED’ uses the technology of

induction furnace to melt down the scraps and waste cast iron procured from

the local dealers. Following are the steps involved in the manufacturing unit of

the organization to make ingots:

• Scraps and waste caste iron are transferred to the induction furnace

unit from the scrap unit with the help of EOT (electrical overhead

travelling) having electromagnet.

Max. Load carrying capacity of EOT is 10 tonnes kg/ per lift.

• At the melting unit, the scraps and other raw materials are mixed in

definite composition for more than 60 minutes. This melted steel in

then poured into the ingots moulds.

• The ingot moulds are the kept for 30-45 minutes for melted steel to be

casted.

• After casting, the moulds are carried away by the EOT cranes fitted

with hoist to the ingots storage section. Moulds are again replaced back

to the casting unit.

TABLE6: FURNACE DETAILS

FURNACE DETAILS

1 RATED CAPACITY(KG) 5

TONNES

2 RATED POWER (KW) 2500

3 INPUT VOLTAGE (V) 660-662

4 TRANSFORMER

CAPACITY (KVA) 3500

5 OUTPUT VOLTAGE (V) 3500

6 MELTING TIME (MINS) 60-70

7 NO. OF FURNACE 2

25

g. PICTURES OF MANUFACTURING UNIT REGARDING INGOTS

MANUFACTURING-

FIG9: EOT with electromagnet lifting scrap and cast iron.

FIG10: At the top table of induction furnace.

FIG11: Control room for the induction furnace.

FIG12: Moulds for the casting of ingots.

FIG13: Combined picture of melting and casting unit

FIG14: Ingots stored at the ingots storage unit for further

processing.

FIG15: Final polished ingots with graphite for better

finishing of finished structure.

26

h. INGOTS MOULDS- Cast iron is used to fabricate the mould. Thermal

coefficient of cast iron is lower than steel as a result, steel on solidification

contracts more than cast iron which makes detachment of ingot easier from the

mould. Inner walls of the mould are coated by tar or fine carbon. The coated

material decomposes during solidification which prevents sticking of solidified

ingots with the inner walls of the mould.

The company uses narrow end up or big end down types of mould as shown in

fig16. But they have partition in between to produce two ingots in single

mold.

FIG16: NARROW END UP MOULD FOR INGOTS CASTING

Narrow end up moulds are commonly used to produce rimming and semi-killed

steel ingots. Narrow-end-up molds facilitate easy escape of rimming reaction

product, CO. Insulating and exothermic materials are put on the top ingot which

ensures availability of hot metal towards the end of solidification. Both bottom

pouring and top pouring of steel are used in ingot casting.

i. INGOTS DEFECTS- CAUSES AND REMEDIES

i. PIPE FORMATION:

Cause: Steel contracts on solidification. The volumetric shrinkage leads to

formation of pipe. In killed steels pipe formation occurs toward the end of

solidification. Fig11.1 shows primary and secondary pipe in narrow end up

mould while casting killed steel. Only primary pipe can be seen in wide

end up mould. The rimming and semi-finished steel show very less

tendency for pipe formation as shown in fig11.2.

27

FIG17.1: NARROW END UP MOULD SHOWING LONG PIPE IN

KILLED STEEL

FIG17.2: RIMMING AND SEMI-FINISHED STEEL SHOW VERY

LESS TENDENCY FOR PIPE FORMATION

Remedy: use of hot top on the mold. The volume of the hot top is 10-15%

higher than ingot volume. Pipe formation is restricted in the hot top which can

be discarded. Use of exothermic materials in the hot top keeps the metal hot in

the top portion and pipe formation can be avoided. Another method is to pour

extra mass of metal.

ii. BLOW HOLES:

Cause: Evolution of gas during solidification of steel. Entrapment of gas

produces blow holes in the ingot. Blow holes located inside the ingot can

be welded during rolling. Rimming steels show blow holes due to rimming

reaction between carbon and oxygen. The rimming reaction produces CO,

which when is unable to escape during solidification, produces blow holes.

Semi-killed steels also show tendency to blow hole formation.

Remedy: Control of gas evolution during solidification so that blow hole

forms only within the ingot skin of adequate thickness.

iii. NON METALLIC INCLUSIONS:

Non metallic inclusions are inorganic oxides, sulphides and nitrides

formed by reaction between metal like Fe, Ti, Zn, Mn, Si, Al with non

metallic elements like oxygen, nitrogen, sulphur etc.. An inclusion is a

mismatch with the steel matrix. Fine size inclusions when distributed

uniformly are not harmful. Non deformable inclusions like Al2O3 are

undesirable. Inclusion modification is the remedy to alleviate the harmful

effect of inclusions on properties of steel.

28

iv. INGOT CRACKS:

• Surface cracks are formed due to friction between mold and ingot

surface. The improper design of mold taper and corner radius cause

surface cracks. Different types of cracks are:

• Transverse cracks: They are parallel to the base of ingot and are

formed due to longitudinal tension in the ingot skin. As the aspect

ratio of the ingot increases, tendency to transverse crack formation

increases.

• Longitudinal cracks are formed due to lateral tension in the skin.

They are parallel to vertical axis of ingot. Alloy steels are more

prone to longitudinal cracks than mild steels.

• Sub- cutaneous cracks are internal fissures close to the surface. The

cracks are formed due to thermal shocks.

• Restriction cracks can be near the corner radius of the ingot.

• Smooth corners of the mould and gradual curvature minimize

restriction cracks.

TABLE7: DAILY PRODUCTION

INDUCTION FURNACES (INGOTS) 130-140 TONNES

ROLLING MILL 11” 50-55 TONNES

ROLLING MILL 9’’ 30-35 TONNES

ROLLING MILL 7’’ 15-20 TONNES

ROLLING MILL 6’’ 4-6 TONNES

TOTAL PRODUCTION 240- 250 TONNES

29

6. MANUFACTURING OF PRODUCTS

a. REHEAT AND BULK DEFORMATION- Liquid steel is cast into ingots, which

after soaking at 1280-1300 0C in the soaking pits are rolled in the blooming and billet

mill into blooms/billets or in slabbing mill into slabs. But the organization doesn’t

require forming billets or blooms. They directly use the ingots in process

manufacturing once cooled and stored in ingot storage unit. Firstly the ingots are

divided into equal halves by shearing action and then are fed into reheat furnace. The

ingots are further heated in the reheating furnaces at 1250- 1280 oC . The ingots after

heating to similar temperature are rolled into angles, plain rods, channels etc. Even

though the chemical composition of steel dictates the mechanical properties, its final

mechanical properties are strongly influenced by rolling practice, finishing

temperature, and cooling rate and subsequent heat treatment.

In the hot rolling operation the material passes through two rolls where the gap

between rolls is lower than the thickness of the input material. The material would be

repeatedly passed back and forth through the same rolls several times by reducing the

gap between them during each pass. Plain rolls are used for flat products such as

plate, strip and sheet, while grooved rolls are used in the production of structural

sections, rails, rounded and special shapes. The rolling process, in addition to shaping

the steel into the required size, improves the mechanical properties by refining the

grain size of the material.

Final rolling of structural and bars/rods is done in respective rolling mills.

FIG18: PRIMARY ROLL FOR STRUCTURAL SHAPES.

30

b. PICTURES OF MANUFACTURING UNIT REGARDING REHEAT AND

BULK DEFORMATION-

FIG19: SIDE VIEW OF REHEAT FURNACE

FIG20: INGOTS FED INTO REHEAT FURNACE OF TEMPERATURE

TREATMENT

FIG21: PILED UP POWDERED COAL ACTING AS FUEL FOR REHEAT

FURNANCE

FIG22: BUCKET ELEVATOR, HOOPER AND FEEDER ARRANGEMENT FOR

TRANSPOTING COAL TO REHEAT FURNACE

31

FIG23: SKILLED LABOURS WORKING AT REHEAT FURNACE UNIT

FIG24: SKILLED LABOURS TRANPORTING HEATED INGOTS TO THE

ROLLING MILL

FIG25: SIX STAND ROLLING MILL

FIG26: DIFFERENT ROLLERS USED MANUFACTURING DIFFERENT

PRODUCTS

Rollers for manufacturing angles Rollers for channel manufacturing Rollers for manufacturing thin rods

32

7. DETAILS OF FINAL PRODUCTS MANUFACTURED

All the products are formed by hot roll process. This indicates the following:

• These are low carbon steel.

• The surface on the steel will be somewhat rough.

• Yield strength will be significantly low.

• Machinability of this grade material is poor.

• These steel materials have excellent heat treatability, cold forming, weldability, cost

efficiency.

• They are good for general purpose uses where high strength is not required.

• They doesn’t possess the closer size tolerances that cold rolled does.

TABLE8: PRODUCTS AVAILABLE STOCK DETAIL

Sr.

No.

Name of the

product Available stock size

Standard

length

(feet)

1 Equal leg angles 1" x 1" x 1/4", 2" x 2" x

1/4", 3" x 3" x 1/4" 12'

2 Unequal leg angles 1" x 2" x 1/4", 1-1/4" x

2" x 1/4", 2" x 3" x 1/4" 12'

3 Steel tees 2" x 1-1/4" x 1/4", 3" x

2" x 1/4" 12'

4 Steel Bar Channels

1" x 1/2" x 1/8", 1-1/2"

x 1/2" x 1/8", 2" x 1/2"

x 1/8"

12'

5 Steel Hot Rolled Flats 1/4" x 2", 1/2" x 1-1/2",

1/2" x 2" 12'

6 Steel Hot Rolled Rods 1",1-1/4" 12'

33

• Angles are L-shaped structural steel represented by dimension of sides & thickness.

For e.g. 1”x1”x1/4” means, both the sides of angles are 1 inch & thickness is of ¼

inch.

• Channel is represented by its Web height, Flange width and Thickness of the channel.

• For e.g. 1”x1/2”x1/8” channel means, the Web height = 1 inch, Flange width = ½ inch

and Width = 1/8 inch.

• Representation of Steel hot rolled Flats is done by the Width (W) & the Thickness (T)

of the Flat. For example: When we say 1/4” X 2” FLAT, it means Width = ¼” &

Thickness = 2”.

• Representation of steel hot rolled Rods is done by Diameter (D). For example, 1” D

represents diameter = 1”.

34

8. OTHER COMPLIMENTARY DEPARTMENTS TO

MANUFACTURING UNIT

a. LATHE MACHINING UNIT:

This unit is not directly involved in the production of steel structures. However, this

unit is installed for the maintenance purpose.

In single point cutting of metals, a built up edge (BUE) is an accumulation of

material against the rake face that seizes to the tool tip, separating it from the chip.

The built up edge effectively changes tool geometry and rake steepness. It also

reduces the contact area between the chip and the cutting tool, leading to:

• A reduction in the power demand of the cutting operation.

• Slight increase in tool life, since the cutting is partly being done by the built up

edge rather than the tool itself.

However, the formations of BUEs have negative effects on the quality of the

workpiece, specifically:

• Excessive work hardening at the surface of the workpiece.

• Poor surface finish, since bits of the BUE eventually break off and stick to the

workpiece. These bits tend to be problematic since, due to the work-hardening

they underwent, they are very hardened so become abrasive.

• A reduction in the dimensional control of the process, due to the dynamically

changing geometry of the cutting tool.

Therefore, in the organization they set up this complimentary lathe machining unit

to remove BUE from the rollers and reuse them which will be cost effective.

There are five 12 feet simple V-belt lathe machines. Most general purpose

performed is step turning, grooving, tapper turning and chamfering.

There are two shop cranes available for material handling.

FIG27: (A) USED ROLLERS FROM ROLLING MILLS WHICH WILL

UNDERGO MACHINING (B) ROLLERS AFTER MACHININHG FOR

REUSE (C) GROOVING IS PERFORMED ON A ROLLER OVER LATHE

MACHINE (D) PICTURE OF A ROLLER FITTED BETWEEN LATHE

CHUCK AND TAIL STOCK.

35

(A) (B)

(C) (D)

b. POWDERED COAL STORAGE UNIT

As the name suggest, this unit is basically a storage unit for coal which is the required

fuel for gaining temperature level in reheat furnace. Coal is mainly procured from

local dealers of Meghalaya at Rs.6 per kg.

A bucket elevator is fitted which lift the coal powder to the hopper. The hopper is for

temporary storage for the powdered designed to dump the material into the feeder

from its bottom end by the gravity action. From the feeder as per requirement the coal

is fed into the reheat furnace.

c. INGOT MOLD MANUFACTURING UNIT

The company has setup a ingot mould manufacturing and repairing unit to save time,

dependency on other firm, and making the process more cost effective. This unit

works as per requirement of the molds in the casting unit. Raw materials used for

manufacturing are green sand, refractory inbuilt gating bricks, and bentonite as a

binder. The mould has a single runner at the middle, multiple cavity and two risers on

either side of the mould.

36

9. TIME FACTOR ANALYSIS FOR PRODUCTION OF

INGOTS

a. FOR EOT (ELECTROMAGNETIC):

AVERAGE LOADING CAPACITY- 10 TONNES KG

LOADING TIME (t1l) - 3 MINS

UNLOADING TIME (t1u) - 3 MINS

TRAVELLING TIME BETWEEN WORK STATIONS (t1s) - 6 MINS

RETRACING TIME (t1r) - 3 MINS

NOTICE: since while retracing the path the EOT is free of extra load. Hence it requires less

time for retracing.

b. FOR INDUCTION FURNACE:

MELTING CAPACITY (tfm) - 5 TONNES KG/ 60 MINS

INPUTING TIME (MECHANIZED WORK) (tfi) - 10 MINS

POURING LIQUID METAL RATE (tfp) - 10 MINS

c. FOR CASTING:

CASTING TIME (tcc) - 30 MINS

MOULDS REARRANGEMENTS (BEFORE CASTING) (tcr) - 30 MINS

REMOVAL OF COPE AND DRAG (AFTER CASTING) (tcd) - 10 MINS

d. FOR EOT (MULTIPLE HOISTS):

AVERAGE LOADING CAPACITY- 10 TONNES KG

LOADING TIME (t2l) - 10 MINS

UNLOADING TIME (t2u) - 3 MINS

TRAVELLING TIME BETWEEN WORK STATIONS (t2s) - 6 MINS

RETRACING TIME (t2r) - 3 MINS

NOTICE: since while retracing the path the EOT is free of extra load. Hence it requires less

time for retracing. Here the loading time is greater than the loading time of EOT

(ELECTROMAGNET) because of manual loading.

The process of casting is the highest time consuming process. Therefore, it decides the

rate of production of ingots.

37

e. IDEAL TIME CALCULATION FOR EOT (ELECTROMAGNET),

INDUCTION FURNACE, EOT (MULTIPLE HOISTS)

i. IDEAL TIME FOR INDUCTION FURNACE

The time the furnace has to remain still with no heating process going on to pour the

liquid metal into the mould is the ideal time for induction furnace in one periodic

cycle of manufacturing.

IDEAL TIME (IF) = (tcc+tcd+tcr+t21) - (tfm+tfi)

= (30+10+30+10) – (60+10) = 10 MINS

ii. IDEAL TIME FOR EOT (ELECTROMAGNET)

The time for which the EOT is unused for one periodic cycle of ingot manufacturing

is the ideal time for EOT. Here, the ideal time will be time at rest after retraced from

induction furnace unit till the time to load again from the scrap storage unit in the

consecutive cycle.

IDEAL TIME (IEE) = (tfm+tfi+IF+tfp) – (t1l+t1t+t1u+t1r)

= (60+10+10+20) – (3+6+3+3) = 85 MINS

iii. IDEAL TIME FOR EOT (MULTIPLE HOISTS)

Here the ideal time will be the time period for which the EOT is at rest after

unloading the moulds from casting unit till the loading of moulds for the transporting

to ingots storage unit.

IDEAL TIME (IEH) = (tcc+tcr+tcd+tfp) – (t2l+t2t+t2u+t2r)

= (30+30+10+20) – (10+3+6+3) = 68 MINS

f. DAILY PRODUCTION OF INGOTS

CAPACITY OF ONE INDUCTION FURNACE- 5 TONNES KG

NUMBER OF INDUCTION FURNACE- 2

TOTAL TIME TAKEN BY EACH IDUCTION FURNACE- TOTAL TIME +

IDEAL TIME = 90 MINS

TOTAL WORKING HOURS- 20 HOURS OR 1200 MINS

THEREFORE DAILY INGOTS PRODUCTION IS= (2*5)*1200/90

= 133 TONNES KG APPROX.

g. INGOTS PRODUCTION ANALYSIS PER MOULD

NUMBER OF DOUBLE INGOT MOLDS FITTED WITH COPE AND DRAG- 32

TOTAL KGS OF MOLTEN METAL POURED FROM FURNACE- 5 TONNES KG

HENCE WEIGHT OF ONE INGOT CASTED IS = 5000/(32*2) = 78.125 KGS

38

FOR CONVINIENCE WE ASSUME 75KGS APPROX SINCE METALS WILL BE

LEFT IN THE GATING AND THE RISERS AS WELL.

THEREFORE WEGHT OF ONE INGOT CASTED = 75 KGS

h. FOR POLISHING OF INGOTS

Ingots are polished with graphite so that after bulk deformation the finished product

has better surface finish.

TIME TAKEN TO POLISH ONE INGOT AT A TIME = 3 MINS

i. NUMBER OF PERSONS REQUIRED AT DIFFERENT STATIONS

TABLE9: PERSON REQUIREMENT AT INGOT MANUFACTURING

Unit Number of

persons required Task to perform

EOT CONTROLLER

UNIT 2 persons

Control the timing and

movement of the EOT

INDUCTION FURNACE

UNIT

3 at each furnace

and 1 supervisor

for guidance

To constantly remove impurities

from the furnace and keeping the

nearby surface clean.

INGOT CASTING UNIT At least 5 To hook up moulds, for

arrangements of cope and drag,

INGOT POLISHING

UNIT 2 persons

To coat a layer of graphite over

the casted ingot

INGOT COOLING AND

STORAGE UNIT 3 persons For proper storage management

39

10. TIME FACTOR ANALYSIS FOR REHEAT AND BULK

DEFORMATION

Firstly the ingots are sheared into two equal halves so that temperature distribution is even.

Therefore, weight of each part = 75/2 kgs = 37.5 kgs.

a. FOR REHEAT FURNACE

TEMPERATURE RANGE- 1280 TO 1300 OC

TIME TAKEN FOR HEAT TREATMENT (trfh) - 10 MINS

TRANSPORTING TO ROLLING MILLS (trft) - 3MINS

b. FOR 3 HIGH SIX STAND ROLLING MILL

NO. OF TIMES INGOTS PASSING THROUGH ROLLER IN ONE CYCLE- 12

TIME TAKEN FOR BULK DERFORMATION ON EACH ROLLING MILL (trd) -

0.25 MINS (AVERAGED).

ANNEALING TIME (ta) - 2 MINS

TIME TAKEN FOR TRANSPROTATION TO SHEARING UNIT (tt) - 0.5 MINS

c. FOR SHEARING UNIT

TIME TAKEN FOR SHEARING (tS) - 0.083 MINS (AVERAGED)

TIME TAKEN FOR PASSING THE UNIT (tP) - 0.25 MINS (AVERAGED)

TIME TAKEN TO TRANSFER TO STORAGE UNIT- 1MIN/LOT

QUATITY IN ONE LOT OF FINSHED PRODUCT- 10

Since the first step, which is temperature treatment in reheating furnace, is most time

consuming, therefore, rate of production depends upon this.

NOTE: Rate of production for different products differs but up to shearing unit the time

taken is same for production. This is due to the fact that volume remains constant for all the

products but cross sectional areas and length varies. This will learnt in next section.

Hence time taken by the product before reaching shearing unit is = (trfh) + (trft) +

(12*trd) + (ta) + (tt) = 10+3+3+2+0.5 = 18.5 MINS

40

d. NUMBER OF PERSONS REQUIRED AT DIFFERENT STATIONS

TABLE10: NUMBER OF PERSONS REQUIREMENT AT REHEAT AND

BULK DEFORMATION UNIT

Unit Number of persons required

at each unit

INGOT SHEARING

UNIT 3 persons

To load. shear down the ingots

into two equal halves and transfer

to reheat furnace

REHEAT FURNACE

(FEEDER SIDE) 2 persons

To control the federate and stack

the ingots at the back end of the

reheat furnace.

REHEAT FURNACE

(END SIDE) 3 persons

For pushing and pulling out the

halved heat treated ingots and

load to shop cranes for

transportation to rolling mills.

3- HIGH SIX STAND

ROLLING MILL 15 persons

1 personas a supervisor, 12

persons on either side of the

rolling mill, 2 persons for

transferring to rollers with the

help of tongs

ROLLERS No person requirement

SHEARING UNIT 4 persons

1 at the control unit of shearing

machine which is hydraulically

driven, 2 for pile up aside for

storage unit, 1 for proper loading

for tooling.

41

11. CALCULATIONS REGARDING PRODUCTION OF

STEEL PRODUCTS

Taking density (D) of the material of structural steel after bulk deformation be =

0.109kg/cubic inches. Mass (M) of the part of ingot = 37.5 kgs

Therefore, volume produced after rolling for any product is fixed = M/D = 37.5/0.109 cubic

inches = 344 cubic inches approx. Hence [cross-sectional area (A)* length (L)] = 344 cubic

inches.

By the given dimensions we can know the cross sectional area of the product. Therefore,

L=344/(12*A) feet and N=L/2.

TABLE11: TABULATED FORM OF PRODUCED LENGTH

SR.

NO.

PRODUCT

NAME DIMENSIONS

CROSS

SECTI

ONAL

AREA

(SQ.

INCHE

S)

PRODUCED

LENGTH

(FEET)

NO. OF

PIECES ON

STANDARD

SIZE (12’)

(N)

1 EQUAL

ANGLES 1" X 1" X 1/4" 0.5 57 4

2" X 2" X 1/4" 1 28 2

3" X 3" X 1/4" 2.25 13 1

2 UNEQUAL

ANGLES 1" X 2" X 1/4" 0.75 38 3

1-1/4" X 2" X

1/4" 0.8125 36 3

2" X 3" X 1/4" 1.25 24 2

3

STEEL HOT

ROLLED

FLATS

1/4" X 2" 0.5 57

1/2" X 1-1/2" 0.75 38 4

1/2" X 2" 1 28 2

4

STEEL HOT

ROLLED

RODS

1" 0.785 36 3

1-1/4" 1.22 24 2

42

RATES OF PRODUCTION

Up to shearing unit the time taken by every product undergoing bulk deformation is same

which IS 18.5 mins as discussed in previous section. Now number of times required for

shearing will decide the rate of production of products.

Shearing time taken = N*ts, total time taken = 18.5+ (N*ts) MINS

Rate of production = N/ [18.5+ (N*ts)]

Hence a tabulated form has been given:

TABLE12: RATE OF PRODUCTION

SR.

NO.

PRODUCT

NAME DIMENSIONS

PRODUCED

LENGTH

(FEET)

NO. OF

PIECES ON

STANDARD

SIZE

(12’)(N)

SHEARING

TIME

TAKEN

(MINS)

TOTAL

TIME

TAKEN

(MINS)

RATE OF

PRODUCTION

(PIECES/MIN)

1 EQUAL

ANGLES

1" X 1" X 1/4" 57 4 0.332 18.832 4.7

2" X 2" X 1/4" 28 2 0.166 18.666 9.3

3" X 3" X 1/4" 13 1 0.083 18.583 18.3

2 UNEQUAL

ANGLES

1" X 2" X 1/4" 38 3 0.249 18.749 6.25

1-1/4" X 2" X

1/4" 36 3 0.249 18.749 6.25

2" X 3" X 1/4" 24 2 0.166 18.666 9.3

3

STEEL

HOT

ROLLED

FLATS

1/4" X 2" 57 4 0.332 18.832 4.7

1/2" X 1-1/2" 38 4 0.332 18.832 4.7

1/2" X 2" 28 2 0.166 18.666 9.3

4

STEEL

HOT

ROLLED

RODS

1" 36 3 0.249 18.749 6.25

1-1/4" 24 2 0.166 18.666 9.3

43

12. CHALLENGES FACED AND MEASURES TAKEN BY

ORGANIZATION IN MANUFACTURING DEPARTMENT

a. LABOURS

i. High labour dependency-

The different work stations of the department are highly labour dependent. As in India

the labour cost are cheap and the production department of Assam Tubes Limited

follows batch size production hence automation will not be economical. Even for

automation, a constant and dependable power supply is required and the state lack in

this sector. There is shortage and extremely fluctuating power supply due to poor

infrastructure of ASSAM STATE ELECTRICAL DEPARTMENT. But being

dependent on man power workforce, the department has setup a training department

to train new workers and even work on field in the absence of labours due to any

uncertainties.

TABLE13: APPROXIMATE PEOPLE REQUIREMENT IN DIFFERENT

WORK STATIONS

Unit Number of persons required

EOT CONTROLLER UNIT 2 persons

INDUCTION FURNACE UNIT 3 at each furnace and 1 supervisor for

guidance

INGOT CASTING UNIT At least 5

INGOT POLISHING UNIT 2 persons

INGOT COOLING AND STORAGE

UNIT 3 persons

INGOT SHEARING UNIT 3 persons

REHEAT FURNACE (FEEDER SIDE) 2 persons

REHEAT FURNACE (END SIDE) 3 persons

3- HIGH SIX STAND ROLLING MILL 15 persons

SHEARING UNIT 4 persons

TOTAL 43 persons

44

NOTE: The above doesn’t include the workers in the storage unit, lathe machine unit,

and coal storage unit. The above data is an estimated value.

ii. Lack of skilled labour

Even though the labours are easily available at a much viable salary but the working

capacity are quite inefficient. This directly affects the rate and quality of the products

being produced. The training department has been set up for the labours to get trained.

Every workstation has a supervisor for any assistance and guidance to the labours.

Advantages of skilled labours-

i. The rate of production and quality of the products depend on the quality of the

labours and machines used in the various steps. Hence more efficient work

will be achieved by trained labours.

ii. No training department will be required. Hence less effort by the organization

and more fruitful work.

But training the labours has some disadvantages-

i. Cost of extra department (the training department) and extra time have to be

incurred by the company.

ii. If the labours discontinues to work after the training period, the effort made by

the company doesn’t gets paid off. Therefore, the company laid a strategy

stating that very small amount of salary will be paid during the period and the

remaining will be paid after they complete the training and start working in the

field.

b. POWER SUPPLY

List of machineries which requires low or heavy power loads-

i. EOT cranes

ii. Induction furnace

iii. Reheat furnace

iv. Standing and Tandem Rolling mills

v. Coal supply unit

vi. Rollers for material transportation

vii. Lathe machining unit

viii. Shearing unit

From the above list it is seen that almost every unit is dependent on heavy electric

power supply except the casting unit and the storage unit. But due to the inefficient

way of power supply causes a lot of hindrance to the production department.

45

c. RAW MATERIAL

Since the raw material used for manufacturing steel ingots is scrap and cast iron, the

exact composition and evenness cannot be achieved. Scrapes includes old corrugated

sheets, leftovers at construction sites such as TMT rods, rods used for trusses, steel

tubes etc. But despite of unevenness, the easiness and abundance in availability makes

it an upper hand for the organisation. Bringing the same amount of iron ore from

nearby state will cost much higher including the transportation cost.

There are many local distributors who deal with ferrous scraps and the organization

has a great link with them as they are their oldest customers.

d. WEAR AND TEAR OF ROLLERS

Since the process of rolling in the six stands hot rolling machine is a hot process, and

due to bulk deformation process under high pressure there are formation of built up

edges on the surface of the rollers. Hence the rollers of each stand goes under weekly

maintenance in the lathe machining department. The company has setup this extra

unit in order to save time and cost otherwise which would have been benefitted by the

third party.

e. COAL FEEDING TO THE REHEAT FURNACE

The bucket elevator, hooper and feeder have been arranged in the coal storage unit to

feed coal to the reheat furnace as a fuel source. The organisation have installed this to

reduce its human dependency work load. Though the machine doesn’t have to run

continuously along with the reheat furnace but when power is supplied its very much

efficient and only the required amount coal is poured into the furnace to attain a

certain temperature. Hence less temperature variance occurs.

f. SERVICE AND MAINTAINACE COST-

This is a major problem to the company. Any damage to the machinery while working

takes a long time to get repaired as there is no local service centre of the company

from which the machineries are bought. The technicians available locally are not

enough skilled and the organisation doesn’t take risk for better future.

The cost for calling a company’s technician including the loss of time has to be

suffered.

46

13. THREATS

a. MARKET FLUCTUATIONS

Annual production of the varied products solely depends on the demand of the

product in the market. The company has seen very fluctuating demand in the market

during the past few years due to the following:

i. Rapid growth in industrial belts in the North Eastern State from the year 2003-

2007. Hence there was large demand of warehouses, industrial shades, and

civil structures. The pressure to meet market demand was directly on the

production department.

ii. Many other small and medium enterprises of structural steel manufacturing

came into play at the end of the booming period. Hence in order to pursue

their product in the market, costs of the products were reduced. Thus, the

company faced a highly challenged market. The new entrants were

‘Megashakti’ and ‘Biscon’. Again, the company has to sell their products at a

much competitive prices.

iii. Presently, a dull period is faced by the company due to central elections taking

place in the country. Hence a low market demand is seen.

iv. Graph of annual sale(Rs. crore) vs. year of production

b. COMPETITORS:

• Large scale industries like Tata steel, SAIL JSW steel have also a great market setup

through various distributors in the retailing sector. The quality of these large scale

companies is better than SME Company like Assam Tubes Limited. But the price

factor dominates the quality factor at commercial level and the organization has a

upper hand in the it’s limited accessible market. The company has to face completion

125115 110 110

100115 110

0

20

40

60

80

100

120

140

2007 2008 2009 2010 2011 2012 2013

SALE

SALE

from various others small scale industries

Greyshakti, Nezone,Jaiswal Rolling.

Price comparison of Tata

Competitive Strength Grid

FACTORS

ATL

TUBES LTD.)

Product Quality

Market share

Service Quality

Production capacity

Brand name

recognition

Advertising

Management Skills

Variety of Products

Financial Capability

Less than average

Average

More than average

42

44

46

48

44.5

48

PR

ICE

IN

RS

./K

G ASSAM TUBES LIMITED

TATA STEEL

from various others small scale industries BISCON, Megashakti, Virdi Iron,

Greyshakti, Nezone,Jaiswal Rolling.

Price comparison of Tata steel and Assam tubes limited.

ATL (ASSAM

TUBES LTD.) BISCON

ASSAM TUBES LIMITED

TATA STEEL

47

BISCON, Megashakti, Virdi Iron,

MEGHASHAKT

I

48

Positive aspects

i. Since Guwahati is the major city in the North Eastern states of the India and

has a better connectivity to the entire seven sister states, hence being located in

the industrial sector of the city, the organization has a well setup market.

ii. Another advantage is that which is also a measure taken is that the company

has its own retailing shop in the Guwahati city. This gives the organization a

direct link to the customers.

c. POLITICAL AND SOCIAL ISSUES-

Due to infiltration of people from nearby countries like Bangladesh, there are

formations of many small organizations like KMSS, AASU etc. who in favour of

local people organises various campaigns and demands rights from the Assam

government to stop migration and promote employment to their fellow people. This

issue has disrupted the socio economical structure of the state. Thus various uncertain

holidays like ‘Assam bandhs’, Transport strike etc. hamper the business.

People working in the organization are from varied cultures and religions. And in

Assam, compared to the North Western States of the country, the local people follow

various rituals and have religious beliefs and hence many holidays for celebrating

their festivals and performing their customs has to be given.

d. LOW INTEGRATED INDUSTRIES-

North Eastern States have basically SME business structure. The economy of the state

is mainly on the outsourcing business, agricultural supply like tea, fruits etc., Crude

oil supply and refining at Digboi, Guwahati and Numaligarh and coal supply from

Meghalaya. There are very less or say no such industries where the company can

supply its products other than construction sector. Even the company has therefor

limited its products variety and producing all the products for a standard 12 feet

length.

49

14. OPPURTUNITIES

a. HUGE INFRASTRUCTURE DEMAND

i. The North Eastern States are developing at a faster rate. There is huge demand

for new infrastructures like highways, bridges etc.

ii. Various telecom services are getting into the market for this region of the

country, hence more requirement of telecom tower. For example, Reliance Jio,

a company to be launched by the end of this year by Reliance group.

iii. Since outsourcing business have a very good opportunity and consumers are

increasing day by day, requirements of new and bigger storage houses is at the

peak.

iv. Shopping malls, office buildings which have to be constructed at a faster pace

will require structural steel for constructing replacing the reinforced structure

which takes much longer time.

b. AVAILABILITY

i. Scraps and cast iron are easily available here for the fulfilment of raw

materials.

ii. The company has also a great advantage of obtaining coal as Meghalaya is a

good supplier of coal which is used as fuel in reheat furnace.

iii. Labours are easily available at an economical rate starting from about

Rs.3500/per month for permanent work. And daily wages persons charge from

about Rs. 200 to Rs.350 per day depending upon the type of work.

c. OUTSOURCING TO OTHER COUNTRIES

The company even has market in Myanmar, Bhutan and Bangladesh. These nations

are under developing stage and there is also a huge demand for infrastructural reform.

d. ONLINE BUSSINESS GROWTH

Now, customers can easily access our company website and check for product

features, size and specifications and even send us their enquiries. This will help us in

increase in sales.

50

15. FUTURE PALNS

i. Setting up a Re-rolling mill (11 inches) which will increase its production by 50 tons

per day.

ii. They are also planning to produce products like joists and heavy channel which are

rarely produced in North-eastern Region and market ingot moulds in the future. These

products will double our production and increase sales to a great extent.

iii. Also, the company has started procuring our raw material especially sponge iron in

bulk which will help in reducing costs.

iv. UNIQUE SELLING PREPOSITION: Variety of quality products and timely delivery

is our USP. As in North-East , steel manufacturers do not provide a variety of steel

products to their customers

v. TABLE14:COMPANY’S SHORT TERM AND LONG TERM PLAN:

Sl. No. DETAILS PROPOSED

CAPACITY

PROJECT

COST

1. Sponge Iron 2x100 (TDP) 35.00 Cr.

2. Power Generation

(WHRB)

8 MW 40.00 Cr.

3. Induction Furnace 3x10 Ton

(TDP)

25.00 Cr.

4. Rolling Mills TMT 300 TDP 20.00 Cr.

TOTAL 120.00 Cr.

NOTE: TDP-total daily production