AARTI training report

2014

AARTI STEEL

LIMITED

6302014

1

Training Report

Vocational Training In

AARTI STEELS LTD (Ludhiana)

Submitted by

NAME KSHITIJ TIWARI

BRANCH Mechanical Engineering COLLEGE NAME GULZAR INSTITUTE OF

ENGINEERING amp TECHNOLOGY (Ludhiana)

2

ACKNOWLEDGMENT

A well known company with a work force of over thousand employees and having huge

margin of profits highlights the most efficient and smooth working of the organization This

thereby creates an eagerness for its known and law I take this opportunity to express my

deep sense of gratitude and whole hearted thanks for enabling me to undergo the First phase

of the Industrial Training of Engineering For six weeks

I am greatly thankful to ErRAVINDER SINGH HOD OF MECHANICAL

DEPARTMENT for his kind support and guidance to successfully complete my training I

have been highly benefitted by this training and have gained a lot of knowledge about the

various processes and techniques employed in Aarti steels ltd Finally I would like to thanks

all the employees of Aarti steels ltd who have helped me and co-operated with me during

my training However my most sincere a special thanks also goes to the principal of our

college Gulzar Institute of Engineering amp Technology (Ludhiana) Lastly I would like thank

all of them who actively helped me during this course

3

CONTENTS

Sr No Beginning Contents Page No

I Cover page -

II Front Page 1

III Acknowledgement 2

Chapter-1

Electric Arc Furnace

11 Introduction (FURNACE OPERATIONS) 4-11

12 Furnace heat balance 11-13

13 Mechanical systems 13-17

14 Electrodes 17

15 Raw materials for the manufacturing of steels 17-21

Chapter-2

Ladle Refining Furnaces

21 Introduction 22

22 Process 23

Chapter-3

Vacuum Degassing

31 Introduction 24

32 Process 25

Chapter-4

Concast Continuous Machine

41 Introduction 26

42 Process 27

Chapter-5

Boiler

51 Introduction 28

52 Construction 29

53 Working 29

54 Advantages of fire tube boiler 29

55 Disadvantages of fire tube boiler 29

56 Detail of boiler 30-31

Chaper-6

Mechanical Department

61 Introduction 32

62 EOT (electric overhead traveling cranes) 32

63 Compressors 32-35

Chapter-7

Workshop

71 Lathe Machines 36

72 Shaper Machine 37

Chapter-8

Demineralization Plant

81 Introduction 38

82 Process 38

Chapter-9

91 Reference 39

4

Chapter-1

Electric arc furnace


11 FURNACE OPERATIONS

The electric arc furnace operates as a batch melting process producing batches of

molten steel known heats The electric arc furnace operating cycle is called the

5

tap-to-tap cycle and is made up of the following operations

Furnace charging

Melting

Refining

De-slagging

Tapping

Furnace turn-around

Modern operations aim for a tap-to-tap time of less than 60 minutes Some twin

shell furnace operations are achieving tap-to-tap times of 35 to 40 minutes

111 Furnace Charging

The first step in the production of any heat is to select the grade of steel to be

made Usually a schedule is developed prior to each production shift Thus the

melter will know in advance the schedule for his shift The scrap yard operator

will prepare buckets of scrap according to the needs of the melter Preparation of

the charge bucket is an important operation not only to ensure proper melt-in

chemistry but also to ensure good melting conditions The scrap must be layered in

the bucket according to size and density to promote the rapid formation of a liquid

pool of steel in the hearth while providing protection for the sidewalls and roof

from electric arc radiation Other considerations include minimization of scrap

cave-ins which can break electrodes and ensuring that large heavy pieces of scrap

do not lie directly in front of burner ports which would result in blow-back of the

flame onto the water cooled panels The charge can include lime and carbon or

these can be injected into the furnace during the heat Many operations add some

lime and carbon in the scrap bucket and supplement this with injection

The first step in any tap-to-tap cycle is charging into the scrap The roof and

electrodes are raised and are swung to the side of the furnace to allow the scrap

charging crane to move a full bucket of scrap into place over the furnace The

bucket bottom is usually a clam shell design - ie the bucket opens up by

retracting two segments on the bottom of the bucket The scrap falls into the

furnace and the scrap crane removes the scrap bucket The roof and electrodes

swing back into place over the furnace The roof is lowered and then the

electrodes are lowered to strike an arc on the scrap This commences the melting

portion of the cycle The number of charge buckets of scrap required to produce a

heat of steel is dependent primarily on the volume of the furnace and the scrap

density Most modern furnaces are designed to operate with a minimum of back-

charges This is advantageous because charging is a dead-time where the furnace

does not have power on and therefore is not melting Minimizing these dead-times

6

helps to maximize the productivity of the furnace In addition energy is lost every

time the furnace roof is opened This can amount to 10 - 20 kWhton for each

occurrence Most operations aim for 2 to 3 buckets of scrap per heat and will

attempt to blend their scrap to meet this requirement Some operations achieve a

single bucket charge Continuous charging operations such as CONSTEEL and the

Fuchs Shaft Furnace eliminate the charging cycle

112 Melting

The melting period is the heart of EAF operations The EAF has evolved into a

highly efficient melting apparatus and modern designs are focused on maximizing

the melting capacity of the EAF Melting is accomplished by supplying energy to

the furnace interior This energy can be electrical or chemical Electrical energy is

supplied via the graphite electrodes and is usually the largest contributor in

melting operations Initially an intermediate voltage tap is selected until the

electrodes bore into the scrap Usually light scrap is placed on top of the charge to

accelerate bore-in Approximately 15 of the scrap is melted during the initial

bore-in period After a few minutes the electrodes will have penetrated the scrap

sufficiently so that a long arc (high voltage) tap can be used without fear of

radiation damage to the roof The long arc maximizes the transfer of power to the

scrap and a liquid pool of metal will form in the furnace hearth At the start of

melting the arc is erratic and unstable

Wide swings in current are observed accompanied by rapid movement of the

electrodes As the furnace atmosphere heats up the arc stabilizes and once the

molten pool is formed the arc becomes quite stable and the average power input

increases

Chemical energy is be supplied via several sources including oxy-fuel burners and

oxygen lances Oxy-fuel burners burn natural gas using oxygen or a blend of

oxygen and air Heat is transferred to the scrap by flame radiation and convection

by the hot products of combustion Heat is transferred within the scrap by

conduction Large pieces of scrap take longer to melt into the bath than smaller

pieces In some operations oxygen is injected via a consumable pipe lance to cut

the scrap The oxygen reacts with the hot scrap and burns iron to produce intense

heat for cutting the scrap Once a molten pool of steel is generated in the furnace

oxygen can be lanced directly into the bath This oxygen will react with several

components in the bath including aluminium silicon manganese phosphorus

carbon and iron All of these reactions are exothermic (ie they generate heat) and

supply additional energy to aid in the melting of the scrap The metallic oxides

that are formed will end up in the slag The reaction of oxygen with carbon in the

7

bath produces carbon monoxide which either burns in the furnace if there is

sufficient oxygen andor is exhausted through the direct evacuation system where

it is burned and conveyed to the pollution control system Auxiliary fuel

operations are discussed in more detail in the section on EAF operations Once

enough scrap has been melted to accommodate the second charge the charging

process is repeated Once the final scrap charge is melted the furnace sidewalls

are exposed to intense radiation from the arc

As a result the voltage must be reduced Alternatively creation of a foamy slag

will allow the arc to be buried and will protect the furnace shell In addition a

greater amount of energy will be retained in the slag and is transferred to the bath

resulting in greater energy efficiency Once the final scrap charge is fully melted

flat bath conditions are reached At this point a bath temperature and sample will

be taken The analysis of the bath chemistry will allow the melter to determine the

amount of oxygen to be blown during refining At this point the melter can also

start to arrange for the bulk tap alloy additions to be made These quantities are

finalized after the refining period

113 Refining

Refining operations in the electric arc furnace have traditionally involved the

removal of phosphorus sulphur aluminium silicon manganese and carbon from

the steel In recent times dissolved gases especially hydrogen and nitrogen been

recognized as a concern Traditionally refining operations were carried out

following meltdown ie once a flat bath was achieved These refining reactions

are all dependent on the availability of oxygen Oxygen was lanced at the end of

meltdown to lower the bath carbon content to the desired level for tapping Most

of the compounds which are to be removed during refining have a higher affinity

for oxygen that the carbon Thus the oxygen will preferentially react with these

elements to form oxides which float out of the steel and into the slag In modern

EAF operations especially those operating with a hot heel of molten steel and

slag retained from the prior heat oxygen may be blown into the bath throughout

most of the heat As a result some of the melting and refining operations occur

simultaneously

Phosphorus and sulphur occur normally in the furnace charge in higher

concentrations than are generally permitted in steel and must be removed

Unfortunately the conditions favourable for removing phosphorus are the opposite

of those promoting the removal of sulphur Therefore once these materials are

pushed into the slag phase they may revert back into the steel Phosphorus

retention in the slag is a function of the bath temperature the slag basicity and

8

FeO levels in the slag At higher temperature or low FeO levels the phosphorus

will revert from the slag back into the bath Phosphorus removal is usually carried

out as early as possible in the heat Hot heel practice is very beneficial for

phosphorus removal because oxygen can be lanced into the bath while its

temperature is quite low Early in the heat the slag will contain high FeO levels

carried over from the previous heat thus aiding in phosphorus removal High slag

basicity (ie high lime content) is also beneficial for phosphorus removal but care

must be taken not to saturate the slag with lime This will lead to an increase in

slag viscosity which will make the slag less effective Sometimes fluorspar is

added to help fluidize the slag

Stirring the bath with inert gas is also beneficial because it renews the slagmetal

interface thus improving the reaction kinetics In general if low phosphorus levels

are a requirement for a particular steel grade the scrap is selected to give a low

level at melt-in The partition of phosphorus in the slag to phosphorus in the bath

ranges from 5 to 15 Usually the phosphorus is reduced by 20 to 50 in the EAF

Sulphur is removed mainly as a sulphide dissolved in the slag The sulphur

partition between the slag and metal is dependent on slag chemistry and is

favoured at low steel oxidation levels Removal of sulphur in the EAF is difficult

especially given modern practices where the oxidation level of the bath is quite

high

Generally the partition ratio is between 3 and 5 for EAF operations Most

operations find it more effective to carry out desulfurization during the reducing

phase of steelmaking This means that desulfurization is performed during tapping

(where a calcium aluminate slag is built) and during ladle furnace operations For

reducing conditions where the bath has a much lower oxygen activity distribution

ratios for sulphur of between 20 and 100 can be achieved Control of the metallic

constituents in the bath is important as it determines the properties of the final

product Usually the melter will aim at lower levels in the bath than are specified

for the final product Oxygen reacts with aluminium silicon and manganese to

form metallic oxides which are slag components These metallic tend to react with

oxygen before the carbon They will also react with FeO resulting in a recovery of

iron units to the bath

For example Mn + FeO = MnO + Fe

Manganese will typically be lowered to about 006 in the bath

The reaction of carbon with oxygen in the bath to produce CO is important as it

9

supplies a less expensive form of energy to the bath and performs several

important refining reactions In modern EAF operations the combination of

oxygen with carbon can supply between 30 and 40 of the net heat input to the

furnace Evolution of carbon monoxide is very important for slag foaming

Coupled with a basic slag CO bubbles are tapped in the slag causing it to foam

and helping to bury the arc This gives greatly improved thermal efficiency and

allows the furnace to operate at high arc voltages even after a flat bath has been

achieved Burying the arc also helps to prevent nitrogen from being exposed to the

arc where it can dissociate and enter into the steel

If the CO is evolved within the steel bath it helps to strip nitrogen and hydrogen

from the steel Nitrogen levels in steel as low as 50 ppm can be achieved in the

furnace prior to tap Bottom tapping is beneficial for maintaining low nitrogen

levels because tapping is fast and a tight tap stream is maintained A high oxygen

potential in the steel is beneficial for low nitrogen levels and the heat should be

tapped open as opposed to blocking the heat At 1600 C the maximum solubility

of nitrogen in pure iron is 450 ppm Typically the nitrogen levels in the steel

following tapping are 80 - 100 ppm Decarburization is also beneficial for the

removal of hydrogen It has been demonstrated that decarburizing at a rate of 1

per hour can lower hydrogen levels in the steel from 8 ppm down to 2 ppm in 10

minutes

At the end of refining a bath temperature measurement and a bath sample are

taken If the temperature is too low power may be applied to the bath This is not

a big concern in modern melt shops where temperature adjustment is carried out in

the ladle furnace

114 De-Slagging

De-slagging operations are carried out to remove impurities from the furnace

During melting and refining operations some of the undesirable materials within

the bath are oxidized and enter the slag phase It is advantageous to remove as

much phosphorus into the slag as early in the heat as possible (ie while the bath

temperature is still low) The furnace is tilted backwards and slag is poured out of

the furnace through the slag door

Removal of the slag eliminates the possibility of phosphorus reversion During

slag foaming operations carbon may be injected into the slag where it will reduce

FeO to metallic iron and in the process produce carbon monoxide which helps

foam the slag If the high phosphorus slag has not been removed prior to this

operation phosphorus reversion will occur

10

During slag foaming slag may overflow the sill level in the EAF and flow out of

the slag door

The following table shows the typical constituents of an EAF slag

Component Source Composition Range

CaO Charged 40 - 60

SiO2 Oxidation product 5 - 15

FeO Oxidation product 10 - 30

MgO Charged as dolomite 3 - 8

CaF2 Charged - slag fluidizer

MnO Oxidation product 2 - 5

S Absorbed from steel

P Oxidation product

Table 11 Typical constituents of an EAF slag

115 Tapping

Once the desired steel composition and temperature are achieved in the furnace

the tap-hole is opened the furnace is tilted and the steel pours into a ladle for

transfer to the next batch operation (usually a ladle furnace or ladle station)

During the tapping process bulk alloy additions are made based on the bath

11

analysis and the desired steel grade De-oxidizers may be added to the steel to

lower the oxygen content prior to further processing

This is commonly referred to as blocking the heat or killing the steel

Common de-oxidizers are aluminium or silicon in the form of ferrosilicon or

silicomanganese Most carbon steel operations aim for minimal slag carry-over A

new slag cover is built during tapping For ladle furnace operations a calcium

aluminate slag is a good choice for sulphur control Slag forming compounds are

added in the ladle at tap so that a slag cover is formed prior to transfer to the ladle

furnace Additional slag materials may be added at the ladle furnace if the slag

cover is insufficient

116 Furnace Turn-around

Furnace turn-around is the period following completion of tapping until the

furnace is recharged for the next heat During this period the electrodes and roof

are raised and the furnace lining is inspected for refractory damage If necessary

repairs are made to the hearth slag-line tap-hole and spout In the case of a

bottom-tapping furnace the taphole is filled with sand

Repairs to the furnace are made using gunned refractories or mud slingers In most

modern furnaces the increased use of water-cooled panels has reduced the amount

of patching or fettling required between heats Many operations now switch out

the furnace bottom on a regular basis (2 to 6 weeks) and perform the hearth

maintenance off-line

This reduces the power-off time for the EAF and maximizes furnace productivity

Furnace turn-around time is generally the largest dead time (ie power off) period

in the tap-to-tap cycle With advances in furnace practices this has been reduced

from 20 minutes to less than 5 minutes in some newer operations

12 FURNACE HEAT BALANCE

To melt steel scrap it takes a theoretical minimum of 300 kWhton To provide

superheat above the melting point of 2768 F requires additional energy and for

typical tap temperature requirements the total theoretical energy required usually

lies in the range of 350 to 370 kWhton However EAF steelmaking is only 55 to

65 efficient and as a result the total equivalent energy input is usually in the

range of 560 to 680 kWhton for most modern operations

This energy can be supplied from a variety of sources as shown in the table below

12

The energy distribution is highly dependent on local material and consumable

costs and is unique to the specific melt shop operation

A typical balance for both older and more modern EAFs is given in the following

Table

UHP

FURNACE

Low to Medium

Power Furnace

Electrical Energy 50 - 60 75 - 85

INPUTS Burners 5 - 10

Chemical Reactions 30 - 40 15 - 25

TOTAL INPUT 100 100

OUTPUTS

Steel 55 - 60 50 - 55

Slag 8 - 10 8 - 12

Cooling Water 8 - 10 5 - 6

Miscellaneous 1 - 3 17 - 30

Off gas 17 - 28 7 - 10

Table 12 Typical balance for both older and more modern EAFs

Of course the above figures are highly dependent on the individual operation and

vary considerably from one facility to another Factors such as raw material

composition power input rates and operating practices (eg post-combustion

scrap preheating) can greatly alter the above balance In operations utilizing a

large amount of charge carbon or high carbon feed materials up to 60 of the

energy contained in the off gas may be calorific due to large quantities of un-

combusted carbon monoxide Recovery of this energy in the EAF could increase

13

energy input by 8 to 10 Thus it is important to consider such factors when

evaluating the energy balance for a given furnace operation

The International Iron and Steel Institue (IISI) classifies EAFs based on the power

supplied per ton of furnace capacity For most modern operations the design

would allow for at least 500 kVA per ton of capacity The IISI report The Electic

Furnace - 1990 indicates that most new installations allow 900 - 1000 kVA per

ton of furnace capacity Most furnaces operate at a maximum power factor of

about 085 Thus the above transformer ratings would correspond to a maximum

power input of about 075 to 085 MW per ton of furnace capacity

13 MECHANICAL SYSTEMS

Mechanical systems are integral to the operation of the EAF and many are inter-

related To gain a better perspective of the importance of various systems in the

furnace operation it is good to step back and evaluate the function of the electric

arc furnace itself

The EAF has several primary functions

1 Containment of steel scrap

2 Heating and melting of steel scrap

3 Transfer of molten steel to the next processing stage

It is easy to see that the first function scrap containment can only be properly

carried out if the furnace shell is properly maintained The furnace shell consists of

a refractory lined bottom that helps contain the liquid steel and typically a water-

cooled upper section that only comes into contact with scrap and slag

Heating and melting of the scrap are accomplished by supplying electrical energy

through the electrodes and chemical energy through the use of burners and oxygen

lances Transfer of the liquid steel to the ladle is accomplished by tilting the

furnace and opening either a tapping spout or a bottom tap-hole to allow the steel

to flow from the furnace It is apparent that many sub-systems come into play

throughout the tap-to-tap cycle Many of these systems are dependent of the

following systems in order to be able to function properly

Hydraulic system

Cooling water system

Lubrication System

131 Hydraulic system

14

The hydraulic system provides motive power for almost all EAF movements

including roof lowerraise roof swing electrode arms updownregulationswing

furnace tilt forwardbackward slag door raiselower and movement of any

auxiliary systems such as the burner lance The hydraulic system consists of a

central reservoir filters an accumulator hydraulic valves and hydraulic piping As

hydraulic fluid passes through valves in one of two directions within a given

circuit hydraulic cylinders are extended or contracted to provide movement of

various mechanical components

Without sufficient fluid flow and pressure within a circuit movement is

impossible Thus issues such as low fluid level low accumulator pressure system

leaks fluid degradation due to over-heating solids build-up in valves or in

hydraulic lines and wear in mechanical components can lead to poor system

performance and in some cases system failure

132 Cooling water system

Another system that is integral to EAF operation is the cooling water system

Typically there are several cooling systems Some operations require extremely

clean high quality cooling water Transformer cooling delta closure cooling bus

tube cooling and electrode holder cooling are all such applications Typically

these systems will consist of a closed loop circuit which conducts water through

these sensitive pieces of equipment The water in the closed loop circuit passes

through a heat exchanger to remove heat The circuit on the open loop side of the

heat exchanger typically flows to a cooling tower for energy dissipation Other

water cooled elements such as furnace side panels roof panels offgas system

ducting furnace cage etc will typically receive cooling water from a cooling

tower

The cooling circuit typically consists of supply pumps return pumps filters a

cooling tower cell or cells and flow monitoring instrumentation Sensitive pieces

of equipment normally have instrumentation installed to monitor the cooling water

flow rate and temperature For most water-cooled equipment interruption of the

flow or inadequate water quantities can lead to severe thermal over loading and in

some cases catastrophic failure

133 Lubrication System

Many modern furnaces have an automatic system that provides lubrication to

various moving parts based on various events occurring during the tap-to-tap

cycle For example some parts are lubricated every three roof swings following

15

tapping etc Some components such as roller bearings are critical to furnace

operation and are lubricated periodically by hand Some hard to reach locations

are serviced using tubing and remote blocks

AUXILIARY SYSTEMS In addition to the major mechanical systems

associated with the EAF there are also many auxiliary systems that are integral to

furnace operation and performance

Oxygen lance system Over the past 20 years the use of oxygen in EAF

steelmaking has grown considerably In the past when oxygen consumption of less

than 300 cubic feet per ton of steel were common lancing operations were carried

out manually using a consumable pipe lance Most modern operations now use

automatic lances and most facilities now use a non-consumable water-cooled

lance for injecting oxygen into the steel Many of these lances also have the

capability to inject carbon as well

Carbon injection system Carbon injection is critical to slag foaming operations

which are necessary for high power furnace operations Carbon reacts with FeO to

form CO and foam the slag

Oxy-fuel burner system Oxy-fuel burners are now almost standard equipment on

large high-powered furnaces In operations with short tap-to-tap times they

provide an important function by ensuring rapid melting of the scrap in the cold

spots This ensures that scrap cave-ins are kept to a minimum and as a result

electrode breakage is minimized In large diameter furnaces burners are essential

to ensure a uniform meltdown

Non-uniform scrap meltdowns may result in operating delays and lost

productivity The biggest maintenance issue for burners is to ensure that they do

not get plugged with metal or slag The closer burners are mounted to the bath the

greater the risk of them becoming plugged while in a low-fire mode Some burners

are mounted directly in the water-cooled panel while others are mounted in a

copper block If burners are fired at high rates against large pieces of scrap the

flame can blow back on the furnace shell damaging the water-cooled panel Thus

the panel area should be inspected for wear around the burner port If a copper

block is used it will be more resistant to flame blow back but should still be

inspected regularly for wear and cracks

Electrode spray cooling system It is common for electrodes to have a spray

cooling system in order to reduce electrode oxidation Spray rings direct water

sprays at the electrode below the electrode clamp and the water runs down the

16

electrode thus cooling it

Sprays rings can reduce overall electrode consumption by as much as 10-20 In

addition spray cooling usually results in improved electrode holder life and

surrounding insulation Due to the reduction in radiation from the electrode power

cable air hose and hydraulic hose life is also greatly improved

Temperature Sampling System The modern disposable thermocouple was

introduced to steelmaking almost 40 years ago and temperature measurement had

become an integral part of tracking progress throughout the tap-to-tap cycle in

steelmaking Expendable probes are also used for tracking bath carbon content and

dissolved oxygen levels in the steel These tools have enabled the tap-to-tap cycle

to be accelerated by eliminating long waiting periods for lab results thus

increasing productivity

Disposable probes are typically mounted in cardboard sleeves that slide on to a

steel probe(pole) which has internal electrical contacts The disposable probe

transmits an electrical signal to the steel pole which in turn transmits the signal to

an electronic unit for interpretation Almost all probes rely on an accurate

temperature measurement to precisely calculate carbon or oxygen levels Most

facilities keep several spare poles on hand so that they can be quickly replaced if

they have reading problems

Offgas Direct Evacuation System Early offgas evacuation systems were

installed so that the furnace operators could better see what was happening in and

around the furnace Since the early days of EAF steelmaking the offgas system

has evolved considerably and most modern EAF shops now use a fourth hole

direct furnace shell evacuation system (DES)

The term fourth hole refers to an additional hole other than those for the

electrodes which is provided for offgas extraction On DC furnaces with only one

electrode the fume extraction port is sometimes referred to as the second hole It

is important to maintain sufficient draft on the furnace for the following reasons

1 To provide adequate pollution control

2 Excessive shop emissions make it difficult for the crane operator to charge

the furnace

3 Excessive emissions around the electrode ports can result in damage of

hoses cables the electrode holder the furnace delta roof refractory

accelerated electrode wear damage to the electrode spray cooler etc

4 Emissions at the roof ring can result in warping of the roof ring structure

5 Excessive emissions of carbon monoxide to the secondary canopy system

17

may result in explosions in the ductwork downstream

6 Excessive dust build-up may cause arcing between electrode phases

Most DES systems consist of water-cooled duct spray cooling dry duct and may

or may not have a dedicated DES booster fan

14 ELECTRODES

One of the most important elements in the electric circuit and consumable cost in

electric furnace steelmaking are the electrodes The electrodes deliver the power to

the furnace in the form of an electric arc between the electrode and the furnace

charge The arc itself is a plasma of hot ionic gasses in excess of 6000degF

Electrodes come in two forms amorphous and graphitic carbon or graphite

Graphite electrodes are composed of a mixture of finely divided calcined

petroleum coke mixed with about 30 coal tar pitch as a binder plus proprietary

additives unique to each manufacturer This mixture is extruded at approximately

220degF the softening temperature of pitch to form a cylindrical rod known as a

green electrode

The green electrode is now given a controlled bake in a reducing atmosphere at

temperatures as high 1800degF and again impregnated with pitch to increase its

strength and density and lower the electrical resistivity The electrodes are now

ready to be graphitized ie converting the amorphous carbon into crystalline

graphite This is accomplished by passing an electric current through them and

heating them to as much as 5000degF The graphitizing consumes as much as 3000-

5000kWHton of electrode

The final product is strong dense and has a low electrical resistivity Lastly the

electrode is machined to its final shape Into each end of the electrode is a recess

in which threads are machined These are used to accept a threaded nipple

manufactured in the same way so that the electrode column can be lengthened as it

is consumed

Historically electrode consumption has been as high as 12-14 pounds per tons of

steel but through continuous improvement in electrode manufacturing and

steelmaking operations this has been reduced to the neighbourhood 35 to 45

pounds per ton Most electrode consumption is through oxidation and tip

sublimation with some small pieces lost around the connecting joint

A considerable portion is also lost to mechanical breakage caused by scrap scrap

18

cave-ins in the furnace or crushing the electrode into the charge Electrodes are

commonly available in sizes from 15 - 30 inches in diameter varying lengths to 10

feet They come in three grades regular and premium and the newer DC grade

16 RAW MATERIALS USED FOR MAANUFACTURE STEELS

The Commonly used raw materials for the manufacture of billets are scrap from

the different regions of the country and some materials are used to make the

required composition of the material

Different types of scraps that are used to manufacture the billets are as

follows

ROLL IRON The roll iron contains about 2-3 of the carbon It is obtained

from the rolling mills Itrsquos also contains nickel and molybdenum is very small

quantity

MOULD CUTTING The mould cutting also contains 2-3 of the carbon It is

obtained from mould that are rejected in the casting machine

PIG IRON Pig iron is the intermediate product of smelting iron ore with a high-

carbon fuel such as coke usually with limestone as a flux Charcoal and anthracite

have also been used as fuel Pig iron has a very high carbon content typically 35-

45 which makes it very brittle and not useful directly as material except for

limited applications

SHREDDED This is the combination of mild steel and cast iron scrap This is

broken or damaged by certain machines

TURNING AND BORING CHIPS This type of scrap is obtained from the

turning boring operations done on the lathe machine During these operations the

extra material in the form of chips is obtained called as Scrap

SPONGE IRON The Sponge iron is like a small balls used to set the carbon

content of the billets Increase of carbon can be controlled by sponge iron This is

of two types

1COAL BASED

2GAS BASED

19

Other alloying elements are also used according to the need of the customer All

these have different alloying properties and are used to make the composition of

the billet good

EFFECT OF ALLOYING ELEMENTS ON STRUCTURE OF STEEL

Steel is basically iron alloyed to carbon with certain additional elements to give

the required properties to the finished melt Listed below is a summary of the

effects various alloying elements in steel

Carbon The basic metal iron is alloyed with carbon to make steel and has the

effect of increasing the hardness and strength by heat treatment but the addition of

carbon enables a wide range of hardness and strength

Manganese Manganese is added to steel to improve hot working properties and

increase strength toughness and harden ability Manganese like nickel is an

austenite forming element and has been used as a substitute for nickel in the

AISI 200 Series of Austenitic stainless Steel (eg AISI 202 as a substitute for

AISI 304)

Chromium Chromium is added to the steel to increase resistance to oxidation

This resistance increases as more chromium is added lsquoStainless Steelrsquo has

approximately 11 chromium and a very marked degree of general corrosion

resistance when compared with steels with a lower percentage of chromium When

added to low alloy steels chromium can increase the response to heat treatment

thus improving hardens ability and strength

Nickel Nickel is added in large amounts over about 8 to high chromium

stainless steel to form the most important class of corrosion and heat resistant

steels These are the austenitic Stainless steels typified by 18-8 where the

tendency of nickel to form austenite is responsible for great toughness and high

strength at both high and low temperature Nickel also improves resistance to

oxidation and corrosion It increases toughness at low temperatures when added in

smaller amounts to alloy steels

Molybdenum Molybdenum when added to chromium-nickel austenite steels

improves resistance to pitting corrosion especially by Chlorides and Sulphur

chemicals When added to low alloy steels molybdenum improves high

temperature strengths and hardness When added to chromium steels it greatly

20

diminishes the tendency of steels to decay in service or in heat treatment

Titanium The main use of titanium as an alloying element in steel is for carbide

stabilization It combines with carbon to for titanium carbides which are quite

stable and hard to dissolve in steel this tends to minimize the occurrence of inter-

granular corrosion as with AISI 321 when adding appx 025060

titanium the carbon combines with the titanium in preference to chromium

preventing a tie-up of corrosion resisting chromium as inter-granular carbides and

the accompanying loss of corrosion resistance at the grain boundaries

Phosphorus Phosphorus is usually added with Sulphur to improve machinability

in low alloy steels phosphorus in small amounts aids strength and corrosion

resistance Experimental work shows that phosphorus present in austenite stainless

steels increases strength Phosphorus additions are known to increase the tendency

to cracking during welding

Sulphur When added in small amounts Sulphur to improve machinability but

does not cause hot shortness Hot shortness is reduced by the addition of

manganese sulphide which combines with the Sulphur to form manganese

sulphide As manganese sulphide has a higher melting point than iron sulphide

which would form if manganese were not present the weak spots at the grain

boundaries are greatly reduced during hot working

Selenium Selenium is added to improve machinability

Niobium (Columbium) Niobium is added to steel in order to stabilize carbon

and as such performs in the same way as described for titanium

Tantalum Chemically similar to niobium and has similar effects

Nitrogen Nitrogen has the effect of increasing the austenitic stability of stainless

steels and as in the case of nickel an austenite forming element Yield strength is

greatly improved when nitrogen is added to austenitic stainless steels

Silicon Silicon is used as a deoxidizing (killing) agent in the melting of steel as a

result most steels contain a small percentage of silicon Silicon contributes to

hardening of the ferrite phase in steels and for this reason silicon killed steels are

somewhat harder and stiffer than aluminium killed steels

Cobalt Cobalt becomes highly radioactive when exposed to the intense radiation

of nuclear reactors and as a result any stainless steel that is in nuclear service will

21

have a cobalt restriction usually appx 02 maximum

Copper Copper is normally present in stainless steels as a residual element

However it is added to a few alloys to produce precipitation hardening properties

22

Chapter-2


21 LADLE REFINING FURNACES

Ladle Refining Furnaces are a proven technology used for producing alloy steel

desuplhurizing liquid steel and for improving the productivity from a steel plant Ladle

Refining is a post-melting treatment that is after melting in either the Induction Melting

Furnace or Electric Arc Furnace Whenever LRF is installed online liquid metal is

transferred from the main melting source to the LRF at a nominal tapping temperature

and either ArgonNitrogen is purged from the bottom apart from arcing (using

electrodes) on the top to bring about homogeneity of liquid metal composition and

temperature Fused limeCaSi is added to the liquid metal to reduce sulphur and bring it

within acceptable limits And temperature is raised for the next casting operation

Fig 21 Systematic Diagram of LRF

Ladle Refining of liquid metal is a proven technology to produce high quality steel

Ladle Refining Furnaces (LRFs) are used to desulphurise steel remove other impurities

and hold the molten steel for casting operations Without LRFs higher tap temperatures

are normally required from steel making furnaces due to heat losses during transfer and

casting of liquid metal LRF facilitates higher productive time to the melting furnace

besides producing better quality of steel at lower cost

When alloying is done in the LRF the main melting furnace is freed from this activity

providing more productive time to the melting equipment and this external treatment

has a few distinct benefits like reduced alloy consumption better lining life excellent

homogeneity of chemical composition amp temperature and relatively lower energy cost

The normal LRF cycle lasts for about 40-50minutes depending upon the aim and final

chemistry and desired temperature rise Temperature can be raised in the LRF at the rate

23

of 3-4OC per minute depending upon ladle condition and ferroalloy additions that are

carried out

Electrotherm has two different types of Ladle Refining Furnaces to offer viz AC LRF

and DC LRF AC LRF is the conventional LRF and is recommended for sizes of 15T

and above DC LRF find their application where captive power is used for producing

steel viz Diesel Based Generating Sets Gas based Generating Sets and power generated

from WHRB andor FBC And also for smaller heat sizes ie 20T and below

Capacity bull 10 T - 25 T - DC Ladle Refining Furnace

bull 15 T - 150 T - AC Ladle Refining Furnace







By providing a mean to refine outside of the steel making furnace LRF provides many

benefits including reduced alloy consumption uniform temperature amp properties and

lower energy costs In addition a vacuum environment can be attained in LRF which

allows production of high quality alloy steel

Attributes Special attributes of Electrotherms LRF

bull Homogenization Temperature and composition are equalized by stirring

bull Inclusion Flotation Non-metallic inclusions are removed by gentle stirring of the metal Oxygen

levels of 30 particles per million (ppm) can be attained

bull Desulphurization Desulphurization is accomplished by injection of CaSi wire and fluxes

Synthetic slag can also be used to desulphurise up to 0015 in about forty minutes

Capacity bull 10 MT - 25 MT - DC Ladle Refining Furnace

bull 15 MT - 150 MT - AC Ladle Refining Furnace

24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING

Depending on the steel grades to be produced various after treatment methods and

process combinations can now-a-days be applied to modern steel making shops

For some grades of steel vacuum treatment has to be given to the steel to achieve

strict quality parameters Various processes have been developed using vacuum

Application of Vacuum Treatment to Steel Grades Ball Bearing Grades were the

first grades for which the vacuum treatment has been successfully used Today

many manufacturers specify vacuum treatment for these grades To an increasing

extent vacuum treatment has been used for production of low alloy and unalloyed

high quality with the use of these treatment units Another field is the production

of silicon grades

Fig 31 Systemic diagram of VD

Carbon contents in the melt of about 001 permit a reduction of the annealing

times in the continuous annealing furnace to about one half which results in

considerable cost savings The improvement of the degree of cleanliness at the

same time results in an improvement of the magnetic properties For grades with a

higher Si content reladling into a second ladle which was often required for

25

homogenization is avoided by adding the silicon through the degassing vessel It

can generally be noted that today steels for silicon grades are produced largely

with the use of vacuum treatment

The greatly increased quality requirements for rail steels can also be met with

vacuum treatment For these grades with higher strength requirements and thereby

higher manganese contents the hydrogen content has to be reduced in order to

avoid slow cooling to prevent flakes The vacuum treatment enables one to

maintain the required degree of cleanliness and also performs corrections of

analysis The vacuum treatment gives rise to the economical production of a

great number of steel grades But efforts have always been made to reduce the

cost for this additional treatment by a simpler treatment especially in those cases

in which the equipment could only be used at a low capacity or where the

temperature losses during the treatment become critical for the tapping

temperatures of the steel Temperature losses for a vacuum treatment are in the

range of 20-50 Deg C The considerations have been of particular importance

where continuous casting has been increasingly introduced A vacuum treatment

should be an ideal preparatory treatment for many grades to be cast in a continuous

casting machine However this requires higher teeming temperature which make it

particularly problematic to compensate for the additional temperature losses during

vacuum treatment

32 VACUUM DEGASSING PROCESSES Vacuum degassing is practiced in

the steel industry for several purposes They are

To remove hydrogen

To improve cleanliness by removing part of the oxygen

To produce steel of low carbon content ( lt 003)

To produce steels to close chemical composition ranges (including

deoxidizers) and

To control pouring temperatures especially for continuous casting

operations

Vacuum degassing processes in the broadest sense refer to the exposure of molten

steel to a low-pressure environment to remove gases (chiefly hydrogen and

oxygen) from the steel The effectiveness of any vacuum degassing operation

depends upon the surface area of liquid steel that is exposed to low pressure

The mechanisms of hydrogen and oxygen removal from liquid steel are related

directly to surface area Hydrogen removal is a diffusion and partial pressure

phenomenon Oxygen removal is a function of chemical reaction of oxygen with

carbon and the partial pressure of carbon monoxide

The processes by which a degassing treatment is accomplished also achieve a host

of other objectives including composition and temperature control

decarburization micro cleanliness and inclusion morphology Under the

vacuum degassing treatments three processes which primarily use this treatment

arestream degassing recalculation degassing and vacuum degassing in the

ladle

26

Chapter-4


41 CONCAST CONTINOUS CASTING MACHINE IN STEEI PLANT

Concast plant is also called by continuous casting machine(CCM) it can produce billets in

various sizes Continuous casting also called strand casting is the process whereby molten

metal is solidified into a semifinished billet bloom or slab for subsequent rolling in the

finishing mills

Fig 41 Billet coming from CCM

Prior to the introduction of continuous casting in the 1950s steel was poured into stationary

molds to form ingots Since then continuous casting has evolved to achieve improved

yield quality productivity and cost efficiency It allows lower-cost production of metal

sections with better quality due to the inherently lower costs of continuous standardised

production of a product as well as providing increased control over the process through

automation This process is used most frequently to cast steel (in terms of tonnage cast)

Aluminium and copper are also continuously cast

42 PROCESS

Molten metal is tapped into the ladle from furnaces After undergoing any ladle treatments

such as alloying and degassing and arriving at the correct temperature the ladle is

transported to the top of the casting machine Usually the ladle sits in a slot on a rotating

turret at the casting machine One ladle is in the on-cast position (feeding the casting

machine) while the other is made ready in the off-cast position and is switched to the casting

position when the first ladle is empty From the ladle the hot metal is transferred via a

refractory shroud (pipe) to a holding bath called a tundish The tundish allows a reservoir of

metal to feed the casting machine while ladles are switched thus acting as a buffer of hot

metal as well as smoothing out flow regulating metal feed to the molds and cleaning the

metal

27

Metal is drained from the tundish through another shroud into the top of an open-base copper

mold The depth of the mold can range from 05 to 2 metres (20 to 79 in) depending on the

casting speed and section size The mold is water-cooled to solidify the hot metal directly in

contact with it this is the primary cooling process It also oscillates vertically (or in a near

vertical curved path) to prevent the metal sticking to the mold walls A lubricant can also be

added to the metal in the mold to prevent sticking and to trap any slag particles including

oxide particles or scale that may be present in the metal and bring them to the top of the pool

to form a floating layer of slag Often the shroud is set so the hot metal exits it below the

surface of the slag layer in the mold and is thus called a submerged entry nozzle (SEN) In

some cases shrouds may not be used between tundish and mold in this case interchangeable

metering nozzles in the base of the tundish direct the metal into the moulds Some continuous

casting layouts feed several molds from the same tundish

28

Chapter-5

Boiler

51 BOILER

The boiler has a special role to play in manufacturing the billets because due to boiler the VD

process runs and which help to make the quality of billets so that it can be made to

manufacture high speed tool In this plant the boiler is fire tube boiler (Horizontal return

tubular boiler )

52 CONSTRUCTION In fire tube boiler there are 3 flue tube There are electrodes for

sparking in the combustion chamber which gets current by transformer which supplies 14000

volts of current to electrodes In the chamber there is also photocell that senses the light in the

chamber which help to do spark in the chamber There is two fuel pumps one is running and

another is standing by

There are also two water pumps to pump water from DM plant one is in condition running

and another is standing by

Fig 51 Systematic diagram of boiler

There are mounting and accessories in the boiler mounting help to do proper functioning of

boiler and accessories help to increase the efficiency of boiler

29

53 WORKING Its operation is as simple as its construction In fire tube boiler the fuel is

burnt inside a furnace The hot gases produced in the furnace then passes through the fire

tubes The fire tubes are immersed in water inside the main vessel of the boiler As the hot

gases are passed through these tubes the heat energy of the gasses is transferred to the water

surrounds them

Fig 52 Operation in boiler

As a result steam is generated in the water and naturally comes up and is stored upon the

water in the same vessel of fire tube boiler This steam is then taken out from the steam outlet

for utilizing for required purpose The water is fed into the boiler through the feed water inlet

General maximum capacity of this type of boiler is 175 kgcm2 and with a capacity of 9

Metric Ton of steam per hour In a fire tube boiler the main boiler vessel is under pressure

so if this vessel is burst there will be a possibility of major accident due to this explosion

54 Advantages of Fire Tube Boiler

Compact in construction

Fluctuation of steam demand can be met easily

Cheaper than water tube boiler

55 Disadvantages of Fire Tube Boiler

Due to large water the required steam pressure rising time quite high

Output pressure canrsquot be very high since the water and steam are kept in same vessel

The steam received from fire tube boiler is not very dry

In a fire tube boiler the steam drum is always under pressure so there may be a

chance of huge explosion which resulting to severe accident

30

561 Detail of boiler use in aarti steels ltd

Sno Topic Detail

1 Company Transparent energy systems pvt ltd

2 Capacity 10 tons

3 Model Steam star-10000

4 Type Horizontal internal furnace3pass

(combustion pre heatersuper heated

water generatriser)

5 Rate steam output 10000 kghr

6 Safety valve (set pressure) 175 kgcm2(g)

7 Super heater 165 kgcm2(g)

8 Steam condition Super heated at- 225degc

9 No of flue gas passes 3 passes in boiler4 in combust air-air

preheater

10 Heating surface 300sq meter

11 Calorific value Furnace oil - 9710 kcalkg

12 Type of Modulation Step less

13 Turn down Ratio 14

14 Electric supply Ac 3phase 1 neutral

15 Wire connected electric load 93 efficiency

16 Blower 225 Kw

17 Fuel oil pump 375 kw

18 Oil pre heater 18Kw

19 Feed water pump 15Kw

20 Electric consumption

(without OPN)

35kw

21 Feed water ph value 8-9

22 No of safety valve 3

Table 51 Detail of boiler

31

562 BOILER MAINTAINS TIME TABLE IN AARTI STEELS LTD

Sno Descriptions Time interval for maintains

1 Boiler Descaling 1year

2 Blower Inspection 6MH

3 DMP Lower filter 6MH

4 DMP Upper filter 3MH

5 Super Heater cleaning 3MH

6 Air per Heater cleaning 3MH

7 Greasing of pumps 2MH

8 Burner ASSB Cleaning 1MH

9 Nozzle cleaning 2MH

10 Fuel filter cleaning 1WK

11 Fire Tube cleaning 2MH

Table 52 Boiler maintains time table

32

Chapter-6


61 MECHANICAL DEPARTMENT

62 CRANE

Cranes are very important part of this organization all type of scrap raw material put in the

chamber with the help of cranes and then taken to the furnace with the help of cranes after

melting melted material is brought to the CCM for casting purpose with the help of it after

casting the final product is loaded on truck with the help of cranes

Cranes used in this plant EOT (electric overhead traveling cranes)

EOT CRANES A wide range of eot cranes for numerous application is made WHI within

this rang included single and double hook cranes grabbing magnet cranes and other material

handling equipment designed for light medium heavy duty they are made latest Indian

standard specification CIS 3177CIS 4137 these cranes move on the gantry rail fixed to the

gantry girder in this cranes 3 common motion are in Cooperated host cross travel and long

travel in addition hoist and CT machine are lifted on common frame called crab which

moves on the crane girder

MAIN COMPONENTS PROVIDED ON CRANES ARE

Bridge

Cranes traveling mechanisms

Crab

Cabin and electrical equipments

No of EOT --9

Voltage supplied to cranes --440 volts

Capacity of various cranes

10ton- 3 cranes (used in billets area)

155ton-2cranes (used in new scrap yard)

6020ton-1crane (used in EAF)

3510ton-2cranes (used in EAF and LRF section)

2 ton ndash 1crane (used in store )

63 COMPRESSOR

Fans blowers and compressors are machines designed to deliver gas at a pressure higher than

that originally existing Pressure rise working pressure specific speed and mechanical design

33

form the basis of differentiation and classification Initially these machines can be divided

into positive displacement and dynamic categories

The main types of gas compressors are illustrated and discussed below

Fig 61 Type of compressors

Centrifugal compressors They are use a rotating disk or impeller in a shaped housing to

force the gas to the rim of the impeller increasing the velocity of the gas A diffuser

(divergent duct) section converts the velocity energy to pressure energy They are primarily

used for continuous stationary service in industries such as oil

refineries chemical and petrochemical plants and natural gas processing plants Their

application can be from 100 horsepower (75 kW) to thousands of horsepower

Fig 62 Centrifugal compressors

With multiple staging they can achieve high output pressures greater than 10000 psi

(69 MPa)

34

Axial-flow compressors are dynamic rotating compressors that use arrays of fan-

like airfoils to progressively compress the working fluid They are used where there is a

requirement for a high flow rate or a compact design

Fig 63 Axial-flow compressors

The arrays of airfoils are set in rows usually as pairs one rotating and one stationary The

rotating airfoils also known as blades or rotors accelerate the fluid The stationary airfoils

also known as stators or vanes decelerate and redirect the flow direction of the fluid

preparing it for the rotor blades of the next stage Axial compressors are almost always multi-

staged with the cross-sectional area of the gas passage diminishing along the compressor to

maintain an optimum axial Mach number Beyond about 5 stages or a 41 design pressure

ratio variable geometry is normally used to improve operation

Axial compressors can have high efficiencies around 90 polytrophic at their design

conditions However they are relatively expensive requiring a large number of components

tight tolerances and high quality materials Axial-flow compressors can be found in medium

to large gas turbine engines in natural gas pumping stations and within certain chemical

plants

Reciprocating compressors They use pistons driven by a crankshaft They can be either

stationary or portable can be single or multi-staged and can be driven by electric motors or

internal combustion engines

Small reciprocating compressors from 5 to 30 horsepower (hp) are commonly seen in

automotive applications and are typically for intermittent duty Larger reciprocating

compressors well over 1000 hp (750 kW) are commonly found in large industrial and

petroleum applications Discharge pressures can range from low pressure to very high

pressure (gt18000 psi or 180 MPa) In certain applications such as air compression multi-

stage double-acting compressors are said to be the most efficient compressors available and

are typically larger and more costly than comparable rotary units Another type of

reciprocating compressor is the swash plate compressor which uses pistons moved by a

swash plate mounted on a shaft

35

Rotary compressors They are use two meshed rotating positive-displacement helical

screws to force the gas into a smaller space

Fig 64 Rotary compressors

These are usually used for continuous operation in commercial and industrial applications

and may be either stationary or portable Their application can be from 3 horsepower

(22 kW) to over 1200 horsepower (890 kW) and from low pressure to moderately high

pressure (gt1200 psi or 83 MPa)

IN THIS PLANT WE HAVE 3 COMPRESSORS IN WHICH 2 USE FOR ERF AND 1

USED FOR LRF ALL OF THEM MADE UP OF CHICAGO PNEUMATIC INDIA

LTD

36

Chapter-7

Workshop

71 Lathe Machines

A Lathe machine is a tool that rotates a work piece on its axis in order to perform various

operations Tools are applied to the work piece to create an object having a symmetrical axis

of rotation in order to perform actions including cutting sanding knurling drilling or

deformation facing and turning Woodturning metalworking metal spinning thermal

spraying parts reclamation and glass-working are common applications of lathe machines A

lathe machine can also be used to shape pottery as well This is one reason why it is

commonly known as the potters wheel Lathe Machines India has come about popularly

especially because Indians are known for their pottery Moreover the growth in the industrial

sector in India has also given rise to Lathe Machines India Lathe Machines truly play a vital

role in the industrial revolution in India as well as in the rest of the world We provide the

best quality Lathe machines that are not only easy for the user to operate but also act as a

friendly companion of the environment

Fig 71 Lathe machine

THIS PLANT THERE ARE 3 LATHE MACHINE TWO COMES IN MEC

DEPARTMENT 1 FOR LIGHT JOB AND 1 FOR HEAVY JOB 1 LATHE MACHINE

COME UNDER CCM DEPARTMENT

72 SHAPER MACHINE

Introduction The shaper is a machine tool used primarily for

Producing a flat or plane surface which may be in a horizontal a vertical or an

angular plane

Making slots grooves and keyways

Producing contour of concaveconvex or a combination of these

37

Working Principle The job is rigidly fixed on the machine table The single point cutting

tool held properly in the tool post is mounted on a reciprocating ram The reciprocating

motion of the ram is obtained by a quick return motion mechanism As the ram reciprocates

the tool cuts the material during its forward stroke During return there is no cutting action

and this stroke is called the idle stroke The forward and return strokes constitute one

operating cycle of the shaper

Construction The main parts of the Shaper machine is Base Body (Pillar Frame Column)

Cross rail Ram and tool head (Tool Post Tool Slide Clamper Box Block)

Fig 72 Shaper machine

Base The base is a heavy cast iron casting which is fixed to the shop floor It supports the

body frame and the entire load of the machine The base absorbs and withstands vibrations

and other forces which are likely to be induced during the shaping operations

Body (Pillar Frame and Column) It is mounted on the base and houses the drive

mechanism compressing the main drives the gear box and the quick return mechanism for

the ram movement The top of the body provides guide ways for the ram and its front

provides the guide ways for the cross rail

Cross rail The cross rail is mounted on the front of the body frame and can be moved up

and down The vertical movement of the cross rail permits jobs of different heights to be

accommodated below the tool Sliding along the cross rail is a saddle which carries the work

table

Ram and tool head The ram is driven back and forth in its slides by the slotted link

mechanism The back and forth movement of ram is called stroke and it can be adjusted

according to the length of the work piece to be-machined

IN THIS PLANT WE HAVE 1 SHAPER MACHINE (OF HORIZONTAL TYPE)

38

Chapter-8

Demineralization plant

81 DEMINERALIZATION PLANT

The water softer plant is widely used in the industries to soft the water so that it can be used

in EAF etc for cooling purpose the water softener plant has resin which is charges with the

help of salt Once resin is charged with salt then it can be used to soft water

Fig 81 Diagram of DM plant

82 PROCESS 1stly the water and salt is mixed in a tub and the supply of tub and incoming

water is connected to common pipe line and fresh water has a nozzle so that it sucks the salt

when water circulate from it due to salt water the salt water the resin is charged and its gets

bigger in size the resin is cylinder contains 3 Parts of resin and once part is empty to occuply

the charged resin volume salt used for charging resin volume salt used for charging resin is

about 200kg once resin is charges then the fresh water is pursed from the resin and then it

drained down so that the all particle get rid of completely from the resin because the salt

water short circuit in the furnaceThen out cylinder is charged and it ready to soft about

2lakhs ltrs of water

39

Chapter

Reference -9

httpsenwikipediaorg

httpswwwasntorgMajorSiteSections Resourcepdf

httpwwwsteelorg~mediaFilesAISIMaking20SteelArticle20Filesle

arning_2ndrefiningpdf

httpwwwsteelorgenMaking20Steelpdf

FPEdneral Electrometallurgy of steel and ferro alloys

AK chakrabarti Steel Making

Heinz G Muller Iron and steel engineer May 1994 P34

Manfred Haissig Iron and steel engineer May 1994 p25

1

Training Report

Vocational Training In

AARTI STEELS LTD (Ludhiana)

Submitted by

NAME KSHITIJ TIWARI

BRANCH Mechanical Engineering COLLEGE NAME GULZAR INSTITUTE OF

ENGINEERING amp TECHNOLOGY (Ludhiana)

2

ACKNOWLEDGMENT














3

CONTENTS


I Cover page -

II Front Page 1


Chapter-1





14 Electrodes 17


Chapter-2


21 Introduction 22

22 Process 23

Chapter-3

Vacuum Degassing

31 Introduction 24

32 Process 25

Chapter-4


41 Introduction 26

42 Process 27

Chapter-5

Boiler

51 Introduction 28

52 Construction 29

53 Working 29




Chaper-6


61 Introduction 32



Chapter-7

Workshop



Chapter-8


81 Introduction 38

82 Process 38

Chapter-9

91 Reference 39

4

Chapter-1






5


Furnace charging

Melting

Refining

De-slagging

Tapping

Furnace turn-around































6







112 Melting

















increases














7

















113 Refining














simultaneously







8




















high
















9




















minutes




the ladle furnace

114 De-Slagging












10


the slag door



CaO Charged 40 - 60







P Oxidation product


115 Tapping





11


































12




Table

UHP

FURNACE

Low to Medium

Power Furnace




TOTAL INPUT 100 100

OUTPUTS

Steel 55 - 60 50 - 55

Slag 8 - 10 8 - 12



Off gas 17 - 28 7 - 10









13














arc furnace itself
















Hydraulic system


Lubrication System


14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









2

ACKNOWLEDGMENT














3

CONTENTS


I Cover page -

II Front Page 1


Chapter-1





14 Electrodes 17


Chapter-2


21 Introduction 22

22 Process 23

Chapter-3

Vacuum Degassing

31 Introduction 24

32 Process 25

Chapter-4


41 Introduction 26

42 Process 27

Chapter-5

Boiler

51 Introduction 28

52 Construction 29

53 Working 29




Chaper-6


61 Introduction 32



Chapter-7

Workshop



Chapter-8


81 Introduction 38

82 Process 38

Chapter-9

91 Reference 39

4

Chapter-1






5


Furnace charging

Melting

Refining

De-slagging

Tapping

Furnace turn-around































6







112 Melting

















increases














7

















113 Refining














simultaneously







8




















high
















9




















minutes




the ladle furnace

114 De-Slagging












10


the slag door



CaO Charged 40 - 60







P Oxidation product


115 Tapping





11


































12




Table

UHP

FURNACE

Low to Medium

Power Furnace




TOTAL INPUT 100 100

OUTPUTS

Steel 55 - 60 50 - 55

Slag 8 - 10 8 - 12



Off gas 17 - 28 7 - 10









13














arc furnace itself
















Hydraulic system


Lubrication System


14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









3

CONTENTS


I Cover page -

II Front Page 1


Chapter-1





14 Electrodes 17


Chapter-2


21 Introduction 22

22 Process 23

Chapter-3

Vacuum Degassing

31 Introduction 24

32 Process 25

Chapter-4


41 Introduction 26

42 Process 27

Chapter-5

Boiler

51 Introduction 28

52 Construction 29

53 Working 29




Chaper-6


61 Introduction 32



Chapter-7

Workshop



Chapter-8


81 Introduction 38

82 Process 38

Chapter-9

91 Reference 39

4

Chapter-1






5


Furnace charging

Melting

Refining

De-slagging

Tapping

Furnace turn-around































6







112 Melting

















increases














7

















113 Refining














simultaneously







8




















high
















9




















minutes




the ladle furnace

114 De-Slagging












10


the slag door



CaO Charged 40 - 60







P Oxidation product


115 Tapping





11


































12




Table

UHP

FURNACE

Low to Medium

Power Furnace




TOTAL INPUT 100 100

OUTPUTS

Steel 55 - 60 50 - 55

Slag 8 - 10 8 - 12



Off gas 17 - 28 7 - 10









13














arc furnace itself
















Hydraulic system


Lubrication System


14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









4

Chapter-1






5


Furnace charging

Melting

Refining

De-slagging

Tapping

Furnace turn-around































6







112 Melting

















increases














7

















113 Refining














simultaneously







8




















high
















9




















minutes




the ladle furnace

114 De-Slagging












10


the slag door



CaO Charged 40 - 60







P Oxidation product


115 Tapping





11


































12




Table

UHP

FURNACE

Low to Medium

Power Furnace




TOTAL INPUT 100 100

OUTPUTS

Steel 55 - 60 50 - 55

Slag 8 - 10 8 - 12



Off gas 17 - 28 7 - 10









13














arc furnace itself
















Hydraulic system


Lubrication System


14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









5


Furnace charging

Melting

Refining

De-slagging

Tapping

Furnace turn-around































6







112 Melting

















increases














7

















113 Refining














simultaneously







8




















high
















9




















minutes




the ladle furnace

114 De-Slagging












10


the slag door



CaO Charged 40 - 60







P Oxidation product


115 Tapping





11


































12




Table

UHP

FURNACE

Low to Medium

Power Furnace




TOTAL INPUT 100 100

OUTPUTS

Steel 55 - 60 50 - 55

Slag 8 - 10 8 - 12



Off gas 17 - 28 7 - 10









13














arc furnace itself
















Hydraulic system


Lubrication System


14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









6







112 Melting

















increases














7

















113 Refining














simultaneously







8




















high
















9




















minutes




the ladle furnace

114 De-Slagging












10


the slag door



CaO Charged 40 - 60







P Oxidation product


115 Tapping





11


































12




Table

UHP

FURNACE

Low to Medium

Power Furnace




TOTAL INPUT 100 100

OUTPUTS

Steel 55 - 60 50 - 55

Slag 8 - 10 8 - 12



Off gas 17 - 28 7 - 10









13














arc furnace itself
















Hydraulic system


Lubrication System


14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









7

















113 Refining














simultaneously







8




















high
















9




















minutes




the ladle furnace

114 De-Slagging












10


the slag door



CaO Charged 40 - 60







P Oxidation product


115 Tapping





11


































12




Table

UHP

FURNACE

Low to Medium

Power Furnace




TOTAL INPUT 100 100

OUTPUTS

Steel 55 - 60 50 - 55

Slag 8 - 10 8 - 12



Off gas 17 - 28 7 - 10









13














arc furnace itself
















Hydraulic system


Lubrication System


14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









8




















high
















9




















minutes




the ladle furnace

114 De-Slagging












10


the slag door



CaO Charged 40 - 60







P Oxidation product


115 Tapping





11


































12




Table

UHP

FURNACE

Low to Medium

Power Furnace




TOTAL INPUT 100 100

OUTPUTS

Steel 55 - 60 50 - 55

Slag 8 - 10 8 - 12



Off gas 17 - 28 7 - 10









13














arc furnace itself
















Hydraulic system


Lubrication System


14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









9




















minutes




the ladle furnace

114 De-Slagging












10


the slag door



CaO Charged 40 - 60







P Oxidation product


115 Tapping





11


































12




Table

UHP

FURNACE

Low to Medium

Power Furnace




TOTAL INPUT 100 100

OUTPUTS

Steel 55 - 60 50 - 55

Slag 8 - 10 8 - 12



Off gas 17 - 28 7 - 10









13














arc furnace itself
















Hydraulic system


Lubrication System


14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









10


the slag door



CaO Charged 40 - 60







P Oxidation product


115 Tapping





11


































12




Table

UHP

FURNACE

Low to Medium

Power Furnace




TOTAL INPUT 100 100

OUTPUTS

Steel 55 - 60 50 - 55

Slag 8 - 10 8 - 12



Off gas 17 - 28 7 - 10









13














arc furnace itself
















Hydraulic system


Lubrication System


14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









11


































12




Table

UHP

FURNACE

Low to Medium

Power Furnace




TOTAL INPUT 100 100

OUTPUTS

Steel 55 - 60 50 - 55

Slag 8 - 10 8 - 12



Off gas 17 - 28 7 - 10









13














arc furnace itself
















Hydraulic system


Lubrication System


14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









12




Table

UHP

FURNACE

Low to Medium

Power Furnace




TOTAL INPUT 100 100

OUTPUTS

Steel 55 - 60 50 - 55

Slag 8 - 10 8 - 12



Off gas 17 - 28 7 - 10









13














arc furnace itself
















Hydraulic system


Lubrication System


14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









13














arc furnace itself
















Hydraulic system


Lubrication System


14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









14

























tower











15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









15




































16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









16































the furnace






17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









17





14 ELECTRODES










green electrode












is consumed







18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









18









follows



quantity















of two types

1COAL BASED

2GAS BASED

19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









19



the billet good












AISI 304)


















20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









20

































21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









21




22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









22

Chapter-2

























23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









23


carried out


























24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









24

Chapter-3

Vacuum Degassing

31 VACUUM DEGASSING










of silicon grades







25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









25




















vacuum treatment



To remove hydrogen




deoxidizers) and


operations














ladle

26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









26

Chapter-4






finishing mills









42 PROCESS










metal

27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









27













28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









28

Chapter-5

Boiler

51 BOILER




tubular boiler )











29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









29





surrounds them


















30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









30


Sno Topic Detail


2 Capacity 10 tons




water generatriser)






preheater







16 Blower 225 Kw





(without OPN)

35kw




31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









31















32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









32

Chapter-6



62 CRANE














Bridge


Crab


No of EOT --9








63 COMPRESSOR



33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









33













(69 MPa)

34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









34
















plants













35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









35










LTD

36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









36

Chapter-7

Workshop

71 Lathe Machines

















72 SHAPER MACHINE



angular plane



37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









37




















table





38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









38

Chapter-8
















39

Chapter

Reference -9

httpsenwikipediaorg









39

Chapter

Reference -9

httpsenwikipediaorg







