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7/27/2019 The Indian Cold Rolling Industry
1/5
Cover Story
November 201216
An Overview
old-rolled
coils, stripsC and sheets are versatilesteel products that are used as
critical inputs in various
sophisticated industries which
demand very stringent qualityspecifications, high level of
surface finish and close
tolerances in dimensions.
Important
applications of cold-
rolled steel products
are found in the
manufacture of
automotive body,
auto components,
petroleum tankers,
lube grease barrels,bitumen drums,
agricultural and
electrical
appliances, earth
moving equipment, furniture, off ice
equipment, precision tubes, bicycle
components, fabricated parts of
engineering machinery, railway
coaches, locomotives, wagons,
elevators, containers, trucks, coldformed sections etc. Beside these,
the construction sector uses
narrow CR Sheets for cable
armouring tapes, press
formed components and
wided CR Sheets for
building industrial
construction tanks and
containers.
Major consumers of cold-
rolled steel products are the
automobile sector, whitegoods sector, galvanized /
coated steel manufacturers
and the oil sector.
7/27/2019 The Indian Cold Rolling Industry
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November 201218
Cold Rolling of SteelThe method of cold rolling points at
the process of metal forming in which
the shape and structure of steel is being
changed by drawing, extruding,
hammering, pressing, spinning or
stretching at temperatures below thesteel's recrystallisation temperature.
These actions create alterations in the
metal's work which increase its
hardness and tensile strength while
enhancing the surface f in ish,
decreasing ductility and impact
resistance.
Cold Rolling is termed as a process by
which the sheet metal or strip stock is
being introduced among rollers
fol lowed by compressing and
squeezing. The rollers rotate in
opposite directions at a steady space
and they are set apart so that their
width is smaller than the metal sheetingthat is passed through. When the metal
goes through the cold mill process, it is
pressed into a pre-ordered gauge for
finishing.
Advantages of Cold RollingThe major advantages of cold-
rolling operation are as follows :
lCold-rolling refines the metal and
goes on to develop the surface
condition of the strips. It makes steel
more strong.
lThe metal-on-metal procedure
helps to stiffen and reinforces the
properties of steel itself. While thesteel thickness decreases most of the
break down or variable patches that
take place in the heating process are
built-up or annealed by cold rolling.
Cold Rolling Steel Industry inIndia
Leading Indian producers of cold-
rolled steel are now capable of
producing high quality products
comparable to global standards for
high-end applications. They are
con t i nuous ly upgrad ing the i r
technologies with the help of world
majors in their eagerness to face thechallenges of global competition.
New Application AreasIn the new application areas, cold
formed sections are being successfully
produced in India. Tailored blanks for
automobiles and high tensile cold-
Industry Group% Share in Total
Consumption
Auto / Tractor / Cycle 24.0
Drums / Barrels /
Containers12.0
Galvanized/Coated Sheets 12.5
Tube Makers
Furniture Makers
Consumer Durables
5.0
6.5
6.2
Agricultural Implements 4.0
Other Eng. Units 3.0
Machinery Manufacturers 2.6
Electrical Manufacturers
CR Units
Oil Sector
Total
2.4
3.0
12.8
100.0
INDUSTRY GROUPWISE CONSUMPTIONOF CR PRODUCTS
rolled products are being produced by
many leading producers. Many Indian
cold-rolled producers have installed
s ta te-of- the-ar t wor ld-c lass
technologies and are now capable of
producing DD/EDD and other stringent
grades / specifications for high-end
applications.
Major Grade / Specif ications
Applications of CR Products Major
Grade / Specificationwise of CR
Products are Shown in Table 1.
Production for Sale of CR Sheet/ Coils in India
Production for sale is arrived at
after deducting Inter-plant Transfers
(IPTs) and producers own consumptionfrom gross production.
Production for sale of CR Sheets /
Coils in India between 2007-08 and
2011-12 are shown in Table-2.
The growth of 3.22 percent in the
production for sale of CR products in
2011-12 over the previous year is acommendable performance in view of adismal growth of 2.9 percent in themanufacturing sector over 8.9 percenin the above comparative periods.Leading Producers of CRProducts in IndiaThe gross production of CR Sheets Coils by leading Indian producer
between 2009-10 and 2011-12 areshown in Table 3.In 2011-12, the above fineproducers had a share of 42.02 percenin the total gross production of CRproducts in India.ImportsImports of CR products by Indiabetween 2007-08 and 2011-12 arefurnished in Table 4.The drop in imports of 14.49percent in 2008-09 was due to theadverse effect of the global crisis tha
started from October, 2008.The higher imports of CR Sheets coils between 2009-10 and 2011-12was due to a robust demand from
automobile, white goods, galvanisedsteel and oil sectors.Exports of CR Sheets / Coils byIndiaExports of CR Sheets / Coils byIndia between 2007-08 and 2011-12are shown in Table 5.
Year Production for Sale % Change
2007-08
2008-09
2009-10
2010-11
2011-12(P)
4439
4602
5914
6717
6933
==
3.67
28.51
13.58
3.22
TABLE 2 : PRODUCTION FOR SALE OFCR SHEETS / COILS : 2007-08 AND
2011-12 ('000 TONNES)
Grades / Specifications Applications
Full Hard IS:513 Grade O Coated Sheets
Packaging, Household Appliances, Precision Tubes
IS:513 Grades D/DD/EDD
IS:513 Grades O(SK) ID(K)
Automobiles
IRSM 41 Railway Coaches, Wagons
IS:513 O/D with Cu Corrosion Resistant Applications
HSCR 26/35Load Bearing Components of Automobiles, Rolled-formed
Sections, Industrial Storage System, Drums and Barrels.
TABLE 1 : MAJOR GRADE / SPECIFICATION APPLICATIONS OF CR PRODUCTS
7/27/2019 The Indian Cold Rolling Industry
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November 201222
Gross Production DuringProducers
2009-10 2010-11 2011-12 (P)
SAIL
Tata SteelEssar Steel
JSW Ispat
JSWSL
720
1041954
238
1498
683
1095907
209
2496
574
1084820
359
1625
TABLE 3 : THE GROSS PRODUCTION OF CR SHEETS / COILS BY LEADING INDIANPRODUCERS : 2009-10 TO 2011-12 ('000 TONNES)
Year Imports % Change
TABLE 4 : IMPORTS OF CR SHEET / COILSBY INDIA : 2007-08 TO 2011-12
('000 TONNES)
2007-08
2008-09
2009-10
2010-11
2011-12 (P)
821
702
892
1148
1442
==
(-) 14.49
27.07
28.70
25.61
Year Exports % Change
TABLE 5 : EXPORTS OF CR SHEETS / COILSBY INDIA 2007-08 TO 2011-12
('000 TONNES)
2007-08
2008-09
2009-10
2010-11
2011-12 (P)
510
327
345
283
285
==
(-) 35.88
5.50
(-) 17.97
0.71
The negative growth in exports of35.88 percent in 2008-09 was due tothe global crisis that started in October,2008. The negative growth of 17.97percent in 2010-11 and the marginalgrowth in 2011-12 was as a result ofthe Eurozone financial crisis and lack ofdemand in the global market in general.Apparent ConsumptionThe apparent consumption of CRSheets / Coils in India between 2007-08 and 2011-12 are shown in Table 6.The high growth in apparentconsumption of cold-rolled products in
India in 2009-10 and 2010-11 was dueto robust growths and higher demandf rom the consum ing sec torsparticularly the automotive sector.India's automotive sector posted highgrowth of 25.7 percent in production,26.41 percent in domestic sales and17.90 percent in exports in 2009-10
Year Exports % Change
TABLE 6 : APPARENT CONSUMPTIONCR SHEETS / COILS IN INDIA : 2007-08 TO
2011-12 ('000 TONNES)
2007-08
2008-09
2009-10
2010-112011-12 (P)
4730
4966
6344
76148063
==
4.99
27.75
20.025.90
over the previous year. In 2010-11, the
respective growths in production,
domestic sales and exports were 27.45
percent, 26.17 percent and 29.64
percent over the previous year.
Projected Consumption of CRSteel Products upto 2019-20
The projections of World Steel
Associat ion (WSA) on India 's
consumption of CR products up to
2019-20 are shown below :
lCurrent Consumption ('000tonnes) 5.2
lProjected Consumption in 2011-
12 ('000 tonnes) 8.0
lProjected Consumption in 2019-
20 ('000 tonnes) 17.0
lCAGR (%) 2007-08 to 2019-20
10.4
Source : Article by Sushim Banerjee,
Presently Director General, INSDAG, in ISR,
December 2008
Configuration of A Modern ColdRolling Mill
Tata Steel's world-class CR Mill
based at Jamshedpur, Jharkhand
produces Tata Steelium which has been
claimed as world's first branded Cold
Rolled Steel. The Tata Steel CR Mill has
the following facilities for the
manufacture of cold-rolled steel.
(i) 5-Stand 6-Hi Tandem Mill
Supplied by Hitachi of Japan. Its main
features are :
lTandem Mill
l6 Hi UCM
lAutomated Gauge and Shape
Method
lThickness Tolerance + 0.percent
lFlatness 10 / units in blanking
The input material, HR Coils ge
picked and are rolled to Cold Rolle
Steel of desired thickness in a single
continuous automotive operation. Th
Tandem Mill ensures guarantee
number of components per tonne, clea
surface and high productivity.
(ii) Bell Annealing Facilitie
Supplied by LOI of Germany. Its main
features are :
lSuperior and uniform mechanica
properties
lSuperior surface cleanliness
lDehumidated chamber for cooling
and storage of annealed coils (rust-
free surface)
lHydrogen Annealing
The Bell Annealing facilitie
guarantee :
(a) Superior formabilities for end-
products
(b) Even point rust spots are
avoided
In the annealing process, the coil
are imparted the desired properties tosuit varying end applications rangin
from auto appliance to drums and
furniture.
(iii) Single Stand 4-Hi Skin Pas
Mill & Electro Discharge Texturing
Machine, supplied by IHI of Japan an
U.K.
Annealed coils are given a smal
reduction (Less than 1%) in the Skin
Pass Mill. The operation results in the
desired surface roughness imparted in
the strip surface as per custome
specifications. Also, flatness of the
strip is improved.
Its main features are :
l4-Hi Configuration
lWide range of surface finishe
with precise control
lControl of surface, sharpness in
narrow band
7/27/2019 The Indian Cold Rolling Industry
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Skin Pass Mill Its main purposes :lTo suppress yield point elongationlTo impart roughness on striplFor better paintabilitylFor improve the followingmechanical properties :- Hardness- Yield Strength- Ultimate Tensile Strength
- To improve shape (Removingwaviness and centre buckle)Performance of Indian CRIndustry, in H1 of 2012-13The performance of the Indian Cold Rolling industry between April, 2012and September, 2012 (H1 of 2012-13)are shown below :Production for SaleProduction for sale of CR Sheets /
Coils in India during H1 of 2012-13 areshown below :Products
Production for Sale ('000 tonnes)% Change
H1 of 2011-12 H1 of 2012-13
CR Sheets / Coils 3490 (P) 4348 (P) 24.58
Despite various constraints, theIndian Cold Rolling industry hasrecorded a robust growth of 24.58percent in production for sale during H1of 2012-13 over H1 of 2011-12.ImportsImports of CR products during H1 of2012-13 over H1 of 2011-12 are
shown below :Products % Change
H1 of 2011-12 H1 of 2012-13
Imports ('000 tonnes)
CR Sheets / Coils 716 776 8.38
ExportsExports of CR production during H1 of 2012-13
vis--vis of 2011-12 are shown below :
Products % ChangeH1 of 2011-12 H1 of 2012-13
Exports ('000 tonnes)
CR Sheets / Coils 152 199 30.92
Apparent Consumption
Apparent Consumption of CR products by India during H1 of 2012-13 vis--visH1 of 2011-12 are presented below :
Products % ChangeH1 of 2011-12 H1 of 2012-13
CR Sheets / Coils
Apparent Consumption ('000 tonnes)
4114 4969 20.78
CR Coils and Sheets recorded highgrowth of consumption in H1 of 2012-13 among major carbon steel products.Special Features of UpcomingCR Mill at Bokaro Steel PlantAmong the features of the 1.2 Mtpy
capacity Cold Rolling Mill at SAIL'sBokaro Steel Plant in Jharkhand to besupplied by Siemens VAI of Austria arethe Siroll CIS CM and PL product line.The first link of the production chainwill be the tandem cold mill coupled to apickling line. For these products, allcore equipment, critical for the lineperformances, are fully engineered,manufactured and tested at SiemensVAI's European plant, located inMontbrison in France. The state-of-the-art PLTCM of 1.2 Mtpy capacity,will be the first of its kind in India,equipped with heavy gauge laserwelder (LW21H), pickling section,horizontal loopers and side trimmer, 5-stand 6-Hi cold rolling mill and a
carrousel coiler. This Cold Rolling atBokaro Steel Plant will meet thehighest Quality standards in terms ofstrip flatness, strip surface, stripcleanliness and dimentional tolerances.It has been designed to produce highstrength automotive grades including,IF, HSLA, HSS And DP Steels as well aslow carbon steel.
The new Cold Rolling Mill at Bokar
has been scheduled to be operation by
2012-13. Downstream of the Bokaro
PLTCM, SAIL has also invested in an
Electrolytic Cleaning Line (ECL) t
remove the remaining iron fines and o
residues from the tandem mill. The
advanced technology of ECL at Bokarwill ensure outstanding coil cleanlines
before the coils reach the downstream
batch annealing furnace.
Recent Innovations in Indian CRMills
Two major innovations that ar
taking place in the configuration o
Indian cold rolling mills are :
lInstallation of PLTCM
lInstallation of Continuou
Annealing Line (CAL)
Pickling Line Coupled withTandem Mill (PLTCM)
Continuous pickling line couplewith tandem mill provides significan
quality improvement, productivity
yield and cost advantages, thereby
eliminating intermediate storages fo
pickled coils and the necessity of strip
threading for each coil entering th
tandem mill. The combination of these
two lines is a mix of highly efficien
features that ensure excellent quality
results in terms of strip's flatness and
thickness control.
The continuous process eliminate
the necessity to thread the strip head
between two consecutive roll
resulting in higher line productivityreduction of off-gauge materials an
reduction of coil handling.
SAIL's Bokaro Steel Plant i
installing a PLTCM to be supplied by
Siemens VAI. The main features o
Bokaro's PLTCM have already been
mentioned earlier.
lJindal South West Steel Ltd
(JSWSL) has placed an order with SMS
Siemag of Germany for the supply of
PLTCM at its Torangall plant. The mil
will have an annual capacity of 2.3 Mt o
cold strips in widths up to 1890 mm and
will be producing high grade cold rolled
products particularly for the auto
sector.
The scope of supply by SMS Siemag
includes entry section, equipped wit
two pay off real groups with a SMS
Siemag welder which enables those
strip of difficult weldability to be joined
7/27/2019 The Indian Cold Rolling Industry
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together. A tension leveler preparesthe strip for the pickling process in thethree downstream pickling tanks. Theturbulence pickling technology allowsop t imum desea l i ng w i th l owconsumption of energy and acid as wellas reduced maintenance and operatingcosts. In addition, an integratedtrimming shear sets the desired stripwidth and straightens the strip edges.Altogether, three horizontal stripaccumulators are integrated into theline which ensures continuous striptravel.The 5-mill stands of the tandem millare designed as a 6-high stand and areequipped with Continuous VariableCrown / enhanced shifting system(CVC Plus / Ess) technology. The roll-gap adjustment range made availableby this SMS Siemag technology allowsoptimum results as regards strip gaugeand flatness, even when the productrange is extremely broad.In the exit section, the strips arecoiled by a carrousel reel at minimumfinal gauge of 0.3mm. A particularlycompact design is achieved from theexit section of the tandem cold mill bycombining the carrousel reel and thedownstream in-line inspection system.The PLTCM of JSWSL is likely to beoperational by the year 2013.Continuous Annealing LinesThe continuous annealing processrepresents the ideal solution for
processing cold-rolled strip with highproduction rates, high yields andsubstantial energy savings ascompared to the batch annealingprocess. These continuous lines ensuretop material qualities and high processflexibility for the broad range of steelgrades and dimensions. Excellentannealing results, especially in theautomotive sector are achieved thanks to the fully automatedtemperature control, specific annealingcycles and rapid cooling system.The present generation ContinuousAnnealing Lines (CALs) for auto bodyquality strip production generallyconsist of coil receiving and entrysection, a double entry pass section forstrip join ing, vert ical looper,electrolytic cleaning section, annealingfurnace, exit vertical looper, skin passand tension leveling section,
horizontal and vertical inspection
station, cooling section followed by coil
delivery section.
Tata Steel has signed a joint venture
agreement with Nippon Steel of Japan
for setting up a Rs. 2300 crore
speciality steelmaking line the
Continuous Annealing Process line to
produce 600,000 tonnes per year of
automotive grade cold rolled steel.
Tata Steel will hold 51 percent share in
the joint venture.
According to Tata Steel sources the
CAL will be located at Jamshedpur in
Jharkhand state and is likely to be
operational in 2013. This will be the
first continuous annealing line to be set
up in India.
Bhushan SteelBhushan Steel is a leading supplier
of auto-grade steel in India. Expanding
the company's current range of flatproducts for the automotive industry. It
has signaled its intention to set up an
advanced pickling line coupled with
tandem cold mill and a continuous
annealing line (PLTCMECAL) facility at
Odisha, with a capacity of 2 Mtpy.
This line will cater to the
requirements of the automotive
industry by increasing the strength of
steel and producing thinner sections,
this reducing weight which will help to
reduce fuel consumption.
The company has already finalized
the technology side and are now
working on the engineering aspect.
Bhushan has planned to start the
construction of the project in January,
2013.
The company expects to complete
the project in Odhisha in two and half
years from the start of physical
construction.
Changing Pattern of CR ProductDemand
In the last decade or so, the demand
for cold-rolled steel, products has
shown an accelerated growth. The
requirement of the products are also
changing fast. The change in the usageof cold-rolled products is evident in the
following two areas in particular :
lGalvanised / Coated Sheets
lNewer sheets like interstitial free
(IF) and brake hardening (BH) steels
for the automobile sector.
In 2010-11 and 2011-12, theautosector in India has posted robusgrowth. The while good sector, whichwas galvanized sheets, a downstreamproduct of cold-rolled steel in theabove two years has also recordedgrowth. In addition to many stringenapplications of cold-rolled productsanother major imporatance of theseproducts is in their downstreamproducts specially the galvanized steesegment including colour coatedsheets. Major galvanized and coloucoated steel producer have nowi n s t a l l e d s t a t e - o f - t h e - a rtechnologies and are producing highesquality products for high endapplication. Despite a difficult markewith lower global demand and loweglobal prices, the Indian Galvanisedsteel industry's export was over 1million tonnes in 2011-12.ConclusionThe Indian Cold Rolling Industry hadeveloped quite significantly in the las5/6 years. It is now capable oproducing high grade products tostringent specifications required fovarious industries. In particular, theleading producers are keen to producehigh grade automotive steels for theIndian automobile industry which hasrecorded robust growth in recenyears.The setting up of PLTCM andContinuous Annealing Lines (CAL) wi
help the production of high gradematerials in a cost-effective and eco-friendly manner. During the periodfrom April, 2012 to September, 2012(H1 of 2012-13), India's cold-rollingindustry's production for sale waabout 4.35 Mt of CR Sheets / Coils ove3.49 Mt during the same period of theprevious year recording a robusgrowth of 24.58 percent.In the above comparative periodsIndia's apparent consumption of CRproducts at about 5 Mt has registered avery high growth of 20.78 percent ove4.11 Mt.Despite a low growth of themanufacturing sector, the performanceof the Indian Cold-Rolling industryduring H1 of 2012-13 is commendableThe industry will grow from strength tostrength in near future.