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ROLLING: MANUFACTURING PROCESS


    For rolling operations, semis like billets, ingots are heated up to 1200°C to make metal malleable. The hot semis are then subjected to rolling mill operations where with the help of different dies fitted at a number of passes, these are given desired shapes. The technology has been in use since many decades with ongoing modifications aimed towards higher efficiency and better quality.

1) Preparation of raw material:

    Billets and Blooms from Own Induction Furnaces/LRF are the main Raw material for the Plant. The Billets/Blooms are received in the Raw - Material Bay and unloaded with the help of Crane. The Billets/Blooms from the Concast Cooling Bed will be shifted to Billet storage shed. From the Billet storage EOT Crane will shift it to raw material storage. The Billet is cut by the Billet shear into required length for rolling. Billets/Blooms are prepared for charging into the furnace as per the quality and size to be rolled. The Billets/Blooms are kept on the Charging Platform by means of Electric Crane. They are then pushed into the Re-heating Furnace with the help of Charging Roller Table and PUSHER.

2) Re-Heating In Furnace:

    The Billets/Blooms are heated to 1100-1200OC in the Pusher type Re-heating Furnace as they are slowly advancing into the Furnace towards the burners. The Re-heating Furnace is equipped with low air pressure burners, Air Blower, Recuperator, Chimney and Oil preheating and Pumping Unit etc. The Furnace temperature is indicated by Pt-PtRh Thermocouple and Electronic Digital temperature Indicator. The Billet/Blooms is discharged out of the Furnace with the help of Mechanical Ejector. The Billet/Bloom is conveyed by a Roller Conveyor (RC) to the Main Roller Table and then automatically fed into the 1st Pass of Roughing Mill Stand No. I.

3) Roughing Mill/ Intermediate Mill/ Continuous Mill:

    In Roughing Mill, there are 2 Stands driven with the help of Electric Motor, Flywheel and Gear Boxes. Several passes are cut into the Rolls to reduce the material in size and shape. There are also two passes in Intermediate Mill and two passes in Continuous Mill. The cutting of passes in the rolls is very important and it varies with the size, shape and quality of the material to be rolled. PASS DESIGN in a Rolling Mill is very important aspect and experienced FOREMAN or ENGINEER is appointed to take care of it. The material (Billet/Bloom) fed into the bottom passes with the help of Main Roller Table and Turning walls and in the top they are fed with the help of Tilting Table. Approximately 4/6 passes have been provided in No. 1st Stand as per the size to be rolled. After that the material is transferred by sliding rails and Skew Rolls to 2nd Stand and 1 pass is provided in the 2nd Stand.

    From Stand No. 2 the material is taken to 1st stand of Intermediate Mill via Roller Table and Y Table. Intermediate Mill has 2 Nos. Stands driven by Electric Motor. The 1st stand is opposite 2nd Stand of Roughing Mill. For top pass feeding `Y' Table is provided. Next the material is transferred to 2nd Stand of Intermediate Mill by sliding rails Skew Rolls. The material elongates each time it passes through the rolls and area reduction takes place. From Stand No. 2 of Intermediate Mill the material is taken to Continuous Mill No-1 via a Roller Table and then it’s going to Continuous Mill No-2 via a Roller Table. Final shape is given in this Stand and accurate adjustment is required. The material is fed into the mill with the help of roller table automatically and it acquires the desired shape and size and further travels to Cooling Bed via a Roller Table. The temperature at finishing stage is 800/9008C approx. The rolls and guides and fiber bearings in the mill are cooled with the help of water recirculation.

4) Natural Cooling On Cooling Bed:

    The Cooling Bed is Duplex type and fabricated with structural material and in the center C.I. plates are provided with few individually driven rolls in between. After finishing pass the material comes to Cooling Bed via Roller Conveyor. Then it is shifted to one side of the Cooling Bed by Manual Shifting arrangement. When one side is filled up, the other side is used. The first side material is cleared while the other side is being used and vice a versa. The material is cleared via Roller Conveyor and cut into required specific length with the help of Shearing Press.

5) Inspection:

    Inspection is done at every stage of Production by Quality Assurance Department. First, the Raw Material is checked, rolling temperature and finishing temperature is monitored and weight per meter of the rolled section is checked periodically. From the finished material, samples are taken for Physical and Chemical Testing in Laboratory. Care is taken so that sub-standard material is not supplied to customers. After the testing, material is kept ready for Dispatch. Mobile or EOT Crane will do loading in the truck.

6) Stockyard And Dispatch: -

    After cutting the inspected material to specific length it is transferred to stockyard and staked properly with the help of crane. Wherever, straightening is required, it is taken to a straightening M/C, and straightened and then properly staked. From the stacked material samples are taken for quality checks and suitable grading is done, as per Indian Standards. The material is then ready for dispatch.



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