Duggs

Industrial training/Bhushan Power and Steel
COMPANY PROFILE
Our mission is to grow our company by providing innovative strong and high performance products and solutions to meet our global customer needs. Bhushan Steel Ltd formerly known as Bhushan Steel & Strips Ltd. is a globally renowned one of the leading prominent player in Steel Industry.Backed by more than two decades, of experience in Steel making, Bhushan Steel is now Indias 3rd largest Secondary Steel Producer company with an existing steel production capacity of 2 million tones per annums (approx.). It was the vision of the founder; Brij Bhushan Singal, that the first stake was driven into the soil of Sahibabad (Uttar Pradesh) in 1987. His vision helped BSL overcome several periods of adversity and strive to improve against all odds. The company has three manufacturing units in the state of Uttar Pradesh (Sahibabad Unit), Maharashtra (Khopoli unit), and Orissa Plant (Meramandali unit) in India and sales network is across many countries. The company is a source for vivid
variety of products such as Cold Rolled Closed Annealed, Galvanized Coil and Sheet, High Tensile Steel Strapping, Colour Coated Coils , Galume Sheets and Coils, Hardened & Tempered Steel Strips , Billets, Sponge Iron, Precision Tubes and Wire Rod. As one of the prime movers of the technological
revolutions in Indian Cold Rolled Steel Industry, BSL has emerged as the countrys largest and the only Cold Rolled Steel Plant with an independent line for manufacturing Cold Rolled Coil and Sheet up to a width of 1700mm, as well as Galvanized Coil and Sheet up to a width of 1350 mm. In due course of time, BSL has grown incredibly its turnover and production capacity by successive expansions as well as improved realizations with these manufacturing units. The dynamic reason of awesome and unparallel growth of BSL, is rapid integration on the Steel value chain; conceivably, it would be its unwavering
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DhruvDuggal/1021030064
focus on acquiring the latest technology and know how, also the BSLs commitment to provide its customers with the best quality products. Given a vibrant Steel industry dynamics in India, we are on a course to become a fully Integrated Steel & Power Company with market leading offerings in value added Steel in Automotive and White Good Segment with the quality been approved by ISO 9001:2008 & ISO 14001:2004.
FIGURE1.1- GROWTH TRAJECTORY
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FIGURE1.2-MOVING UP THE VALUE CHAIN Bhushan Power & Steel Limited, a fully integrated 2.3 Million TPA Steel making Company with turnover of INR 5020 Crores (USD 1123 Million) and 7 World Class ISO 9000 Certified State of the Art Plants at Chandigarh, Derabassi, Kolkata and Orissa in India. A leading manufacturer of flat, rounds and long products including value added products with total steel value chain right from Coal Mining, Billets, HR Coils, Pig Iron, CR Coils, GP/GC, Precision Tubes, Black Pipe/GI Pipe, Cable Tapes, Tor Steel, Wire Rod Bright Bars and Special Alloy Steel. Successfully commissioned 2.3 Million TPA Greenfield Steel and Power
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Plant
in
Orissa
with
HR
Coil
making
facility
First in Private Sector in the State of Orissa. For the Orissa plant, technology and equipments are procured from world-renowned companies like Lurgi from Germany, ABB Ltd., SMS Siemag etc. Bhushan is selling its Value added range of products in Secondary Steel through a large distribution network in India (comprising more than 50 sales offices) and Abroad. A rock-solid foundation combined with continuous upgradation and innovation has ensured that we have constantly surpassed our goals. Our end-to-end portfolio offers a wide spectrum of products with consistently superior quality. In addition to our export thrust, we supply to fastgrowing sectors like automotive, white goods, construction, furniture, fasteners,telecommunication,etc.
Among our major and valued customers in India are Hero Honda, Honda Scooters, Yamaha Motorcycles, JBM, Bajaj Autos, Polar Industries, GE Motors, Amtek, Hindustan Motor, Hero Cycles, Avon Cycles, Atlas Cycles, Delton Cables, Finolex Cables, Sterlite, Paramount Cables, TVS, Suzuki, Omax Auto, Maruti Udyog Ltd. etc.
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Bhushan's products are being exported to Austria, Bhutan, Beinhoa City, Belgium, Congo, Cotondu, Dubai, England, France, Freetown, Gambia, Kuwait, Lebanon, Liberia, Luanda, Malaysia, Monrovia, Nepal, Nigeria, Oman, Singapore, Saudi Arabia, Sri Lanka, South Africa, Senegal, Sierra Leone, Switzerland, Tanzania, Tamatave, U.A.E and Vietnam. GROWING FROM STRENGTH TO STRENGTH: 1970 - Started with very small initial outlay for manufacturing Door Hinges & later on, Rail Track Fasteners. 1973 - Manufacturing facilities set up for Tor Steel and Wire Rod in Chandigarh. 1981 - Rolling Mill Project commissioned at Chandigarh for Round and Narrow Strips. 1985 - Backward Integration Project for Steel Melting facilities. 1986 - Upgrading of Mini Steel Plant with continuous casting and ladle furnace facilities. 1997 - Commissioning of Narrow Width Cold Rolling Project at Chandigarh. 1998 - Commissioning of Precision Pipe Project at Chandigarh. 2001 - Commissioning of Cold Rolling & Galvanizing Complex at Kolkata.
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2002 - Addition of narrow width Cold Rolling facilities at Kolkata. 2003 - Expansion of wide width Cold Rolling facilities, ERW Water Pipes & Tubes down stream facilities at Kolkata. 2004 - Further expansion of Cold Rolling facilities at Kolkata. 2005 - Commissioning of Orissa Project Phase-I consisting of 4 DRI Kilns, Steel Making Facilities, Coal Washery and 100 MW Power Plant. 2007 - Commissioning of further expansion of Orissa Project Phase-II consisting of HR Coil Mill, Steel making, Blast Furnance, Sinter plant, Coke oven plant, Oxygen plant and Lime & Calcining Plant. 2009 - Commissioning of 3.5 million tpa Coal Washery, 146 MW Power Plant and 0.3 million tpa Sponge Iron under Phase III of Orissa Project. 2010 - Commissioning of 130 MW Power Plant and Electric Arc Furnace under Phase III of Orissa Project and further expansion of Orissa Project under Phase IV consisting of 6 DRI Kilns, 130 MW Power Plant, Steel Making Facilities,2nd CSP Caster & 6th strand along with Tunnel Furnace, Oxygen Plant, Lime Calcining with downstream facilities - Cold Rolling, Galvanizing, Galvalume, Colour Coating, Precision Tube & Black Pipe/GI Pipe. 2011 - Commissioning of two DRI Kilns, Electric Arc Furnace, 2nd CSP Caster & 6th Strand along with Tunnel Furnace, Cold Rolling Mill Complex and Galvanising under Phase-IV of Orissa Project.
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MISSION AND VALUES

Our Mission is to achieve clear identity and leadership globally in Steel production and distribution by integration of complete chain of production starting from captive iron ore to end user Steel products. Our revolution in Steel production has helped us to carve a niche unique only to a market leader. Every year passes by with new value additions and more accolades from our customers - Locally and Globally. Our rising chart in respect of all-important parameters of production and finance is a testimony to our claim. In pursuing our mission, we at Bhushan Power & Steel Ltd. are guided by the following values Quality - To be the best in quality. We aim and achieve excellence. Technology - State of the art technology and product enrichment by continuous Research and Development. Customer Friendly - Our products are world class and more and more clients are appreciating and using our products. We also undertake customized products with values addition and enhancement. Corporate Governance - We comply with all applicable laws and regulations. We believe in maintaining clean environment and conservation of natural resources. We contribute towards betterment of our staff and provide them with best of facilities. Environment Protection and Practice - We are adopting and implementing pollution control measures as a matter of policy.
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Company Commitments
To improve the quality of our products and complete integration of various stages of production.
To be conscious towards quality and pricing of our products. We strive by continuous research and development to make our products world class, having distinct identity and uniqueness. Our customers get best value for their money.
To run the company profitably year after year. A workforce motivated, skilled and well looked after. A workplace safe, secure and hygienic. To make our Environment Clean and healthy.
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ROLLING
Objective-To perform rolling process on a lead bar in order to observe the change in both the cross-sectional area and the general shape. TheoryDefinition Flat rolling or Rolling is defined as the reduction of the cross-sectional area of the metal stock, or the general shaping of the metal products, through the use of the rotating rolls. It allows a high degree of closed-loop automation and very high speeds, and is thus capable of providing high-quality, close tolerance starting material for various secondary sheet metal working processes at a low cost .
FIGURE1.3 SCHEMATIC DRAWING OF ROLLING PROCESS
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The rolls rotate as illustrated in Figure 1.3 to pull and simultaneously squeeze the work between them. The basic process shown in Figure 1.3 is flat rolling, used to reduce the thickness of a rectangular cross section.
FIGURE1.4-VARIOUS CONFIGURATIONS OF ROLLING MILLS: (a) two high, (b) three high, (c) four high, (d) cluster mill, and (e) tandem rolling mill
Various rolling mill configurations are available to deal with the variety of applications and technical problems in the rolling process. The basic rolling mill consists of two opposite rotating rolls and is referred to as a two-high rolling mill (Figure 1.4a). In the three-high configuration Figure 1.4(b), there are three rolls in a vertical column, and the direction of rotation of each roll remains unchanged. To achieve a series of reductions, the work can be a passed through from either side by raising or lowering the strip after each pass. The equipment in a three-high rolling mill becomes more complicated, because an elevator mechanism is needed to raise and lower the work .
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Roll-work contact length is reduced with a lower roll radius, and this lads to lower forces, torque, and power. The four-high rolling mill uses two smaller diameter rolls to contact the work and two backing rolls behind them. Another roll configuration that allows smaller working rolls against the work is the cluster rolling mill. To achieve higher throughput rates in standard products, a tandem rolling mill is often used. This configuration consists of a series of rolling stands. With each rolling step, work velocity increases, and the problem of synchronizing the roll speeds at each stand is significant. General Overview of Process The primary objectives of the flat rolling process are to reduce the cross-section of the incoming material while improving its properties and to obtain the desired section at the exit from the rolls. The process can be carried out hot, warm, or cold, depending on the application and the material involved. The rolled products are flat plates and sheets. Rolling of blooms, slabs, billets, and plates is usually done at temperatures above the recrystallization temperature (hot rolling). Sheet and strip often are rolled cold in order to maintain close thickness tolerances. Basically flat rolling consists of passing metal between two rolls that revolve in opposite directions, the space between the rolls being somewhat less than the thickness of the entering metal. Because the rolls rotate with a surface velocity exceeding the speed of the incoming metal, friction along the contact interface acts to propel the metal forward. The metal is squeezed and elongated and usually changed in cross section. The amount of deformation that can be achieved in a single pass between a given pair of rolls depend on the friction conditions along the interface. If too much is demanded, the rolls will simply
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skid over stationery metal. Too little deformation per pass results in excessive cost. Rolling involves high complexity of metal flow during the process. From this point of view, rolling can be divided into the following categories :
Uniform reduction in thickness with no change in width: Here, the deformation is in plane strain, that is, in the directions of rolling and sheet thickness. This type occurs in rolling of strip, sheet, or foil. Uniform reduction in thickness with an increase in width: Here, the material is elongated in the rolling direction, is spread in the width direction, and is compressed uniformly in the thickness direction. This type occurs in the rolling of blooms, slabs, and thick plates. Moderately non-uniform reduction in cross section: Here, the metal is elongated in the rolling direction, is spread in the width direction, and is reduced non-uniformly in the thickness direction. Highly non-uniform reduction in cross section: Here, the reduction in the thickness direction is highly non-uniform. A portion of the rolled section is reduced in thickness while other portions may be extruded or increased in thickness. As a result, in the width direction metal flow may be toward the center.
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HOT ROLLING: The distinctive mark of hot rolling is not a crystallized

structure, but the simultaneous occurrence of dislocation propagation and softening processes, with or without recrystallization during rolling. The dominant mechanism depends on temperature and grain size. In general, the recrystallized structure becomes finer with lower deformation temperature and faster cooling rates and material of superior properties are obtained by controlling the finishing temperature . Hot rolling offers several advantages :
Flow stresses are low, hence forces and power requirements are relatively low, and even very large workpieces can be deformed with equipment of reasonable size. 1) Ductility is high; hence large deformations can be taken (in excess of 99% reduction). 2) Complex part shapes can be generated.
The upper limit for hot rolling is determined by the temperature at which either melting or excessive oxidation occurs. Generally, the maximum working temperature is limited to 50C below the melting temperature. This is to allow the possibility of segregated regions of lower melting material [4].
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COLD ROLLING: Cold rolling, in the everyday sense, means rolling at

room temperature, although the work of deformation can raise temperatures to 100-200C. Cold rolling usually follows hot rolling. A material subjected to cold rolling strain hardness considerably. Dislocation density increases, and when a tension test is performed on this strain-hardened material, a higher stress will be needed to initiate and maintain plastic deformation; thus, the yield stress increases. However, the ductility of the material as expressed by total elongation and reduction of area drops because of the higher initial dislocation density. Similarly, strength coefficient rises and strain-hardening exponent drops. Crystals (grains) become elongated in the direction of major deformation .
Cold rolling has several advantages : 1) In the absence of cooling and oxidation, tighter tolerances and better surface finish can be obtained. 2) Thinner walls are possible. 3) The final properties of the workpiece can be closely controlled and, if desired, the high strength obtained during cold rolling can be retained or, if high ductility is needed, grain size can be controlled before annealing. 4) Lubrication is, in general, easier.
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ROLLING PROBLEMS AND DEFECTS:

The main problem during rolling process is the calibration of rollers. This calibration faults may occur in case of used bearings and may affect the thickness of parts. A simple classification is as here below:
a. Lengthwise Occurring Defects Change of rollers speed Material temperature Roller temperature Inlet thickness Material properties Eccentric and conical rollers Used bearings b. Transversally Occurring Defects Parallel position of rollers Surface geometry of rollers
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ADVANCED TECHNOLOGY IN SKIN PASS ROLLING:
The increased requirements demanded of cold-rolled strip in terms of mechanical properties and surface quality have meant that skin pass rolling, as the last step in the process chain, has become more important. New developments in control of flatness and surface quality, together with increased plant flexibility to handle a diverse range of products are described.
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Against the background of a global market, rolling-mill owners are under constant pressure to cut their production costs and to open up new market segments with the help of innovative products. At the same time, requirements in terms of strip quality, such as thickness and flatness tolerances, surface structure and mechanical properties, are becoming increasingly strict. SMS Siemag, as a provider of complete solutions for rolling mill equipment, is faced with the challenge of taking appropriate measures to help achieve these targets. Therefore, conducting continuous and wide-ranging development activities is indispensable to SMS Siemag. Long-standing solutions need to be questioned and new technologies examined for their usability and benefits in rolling mills. With regard to skin pass rolling, our main areas of development are: ` Improving flatness and surface quality ` Increasing flexibility to handle high-strength material such as DP1000 as well as very soft material like interstitial-free (IF) grades
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` Improving the automation by process models and control systems based on innovative online measurement devices
USE OF LOW VOLUME LUBRICATION AND LIQUID NITROGEN :

SMS Siemag has developed, together with Air Products, REBS and C D Wlzholz, a new lubrication and cleaning concept involving a combination of low-volume lubrication and the utilisation of liquid nitrogen in skin pass rolling. This concept significantly improves the strip surfaces and minimises operating costs. The low-volume lubrication system applies the lubricant in the skin-pass stand entry. This reduces the friction in the roll gap and hence the roll force, and improves flatness while using a minimum amount of lubricant. The liquid nitrogen in the exit covers both the strip and the roll This method has the following advantages: ` Clean and dry strip surfaces and thus lower susceptibility to rust ` Clearly reduced efforts in the downstream steps for cleaning the strip surface ` Extended work roll service lives
Low-volume lubrication: Considering the fundamentals of lubrication

according to Stribeck , cold rolling takes place in the area of boundary lubrication. This means the roll and strip come into occasional contact. Surplus lubrication with higher speed causes more lubricant to be drawn into the roll gap, hence roll and strip are better separated by lubricant pockets, but this causes imprints of the lubricant on the strip surface.
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With low-volume lubrication, which applies around 0.3 0.4ml/m, only a film is produced, which is thinner than the combined roughness of the strip surface and roll, and so these imprints are avoided. The major components of the low-volume lubrication system are very compact and comprise the nozzle beam, a volume controller and the tank, pump and control unit. Two nozzle beams are installed: one for the top and one for the bottom strip surface. Due to the small amount of lubricant, its equal distribution can only be ensured by atomising it with compressed air. The volume controller ensures a constant flow rate during operation. Three configurations are available: one controller for each nozzle, one for a group of nozzles and one for a single nozzle beam. Figure also shows the assessment of the strip surface quality rolled with and without low-volume lubrication. In both cases the same material was rolled. The typical imprints of the lubricant cannot be observed and the strip surface quality is fully comparable. In addition, low-volume lubrication means that roll force is reduced as even a very small amount of oil causes a remarkable decrease in roll force . By varying the amount of oil over a considerable range the roll force can be adjusted. This opens up new options in controlling skin pass rolling. LIQUID NITROGEN: Typical installation consists of vaporiser and nitrogen tank, which are installed outside the mill building. The tank is connected to the nozzle system via a vacuum jacketed line and supply is controlled via valves . To assess the strip surface quality using liquid nitrogen, the same material was skin-passed under different operating conditions . In the pass with emulsion (left), clear impressions of the lubricant were found. They make the surfaces appear less bright. The roll abrasion in dry skin pass rolling has a similar effect
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REWIND CUM TRIMMING LINE:

Built from the basic elements of the compact trimming line, the modular line mechanically trims the edges through chip removal process. Any desired dimension is possible depending on strip width and thickness. The number of tools operating simultaneously is variable.
Specification :
Type Line Material Strip Thickness Strip Width Coil O.D. Coil Wt. Line Speed of Tight Line With Driven Trimmer. CRFH / CRCA. 2.0 MM. 1250 MM. 2000 MM. 25 T. 500 MPM.
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CUT TO LENGHT LINES:

Precision cut-to-length lines are meant for ferrous and non-ferrous rolling mills, service centers, toll processors, industrial and automotive users. Cut to length lines perform a variety of operational functions including cut sheet levelling, edge trim, cut to length, and stack sheets and plates. The application varies from the heaviest hot rolled plate coils to light gauge cold rolled steel, aluminum and copper alloys - often with sensitive or polished surfaces. Multi-blanking lines with options such as continuous 'slitting and shearing' with electronic stacking facility, are also available.
Specification :
Type Line Material of Loop Start Stop. Tight Start Stop. Hot CRFH Rolled / M.S. / /
CRCA
GALVANIZED COLOUR COATED. Strip Thickness Strip Width Coil O.D. Coil Wt. Line Speed No. Cuts of 6.0 MM.
(H.R.)
3.0 MM (C.R.) 1650 MM. 2000 MM. 30 T. 30 MPM. (H.R.)
100 MPM (C.R.) 15 Cuts / Minute (H.R.). 40 Cuts / Minute 27
(C.R.). Sheet Length 6000 MM (H.R.)
5000 MM (C.R.)
FEATURES:

Multi-Roll precision leveller with Back - up roll banks. Pack lifter & shifting Trolley arrangement.
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COIL BUILDUP LINES:

The coil build-up lines are used for side-trimming of the strips and also provide the coils with leader strips that can be reused for optimization of the yield. With suitable inclusion of welder, these lines can be used for building up bigger coils from small coils, with roll-able weld.
VARNISH COATING LINES:

Varnish coating lines are highly resistant to corrosion and have long life. They are equipped with motorized fine adjustments of the rolls, enabling precise positioning. Linear position sensors are placed for reproducible setting of stored reference values even if the product is changed. Pass-line roll is used to keep the strip flat for two-side coating. Mobile coater heads are also used to facilitate roll and vat removal, cleaning and maintenance work, and presetting of specific production parameters.
SKIN PASS MILL:

These skin pass mills are specifically designed for manufacturing sheet / strip of medium hardness or to provide finish pass. The Rolls are made of alloy steel & have high hardness, which is generally up to 65 HRC or more. For increasing demands with respect to strip flatness, elongation and roughness, especially for hard material grades, skin-pass mill is an ideal solution due to higher rolling forces and torques that can be achieved in this case.
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PICKLING LINES:
These pickling lines can process strips varying from 1.0mm to 12.0mm thick and 200mm to 2000mm wide. Picking lines process one coil at a time, therefore eliminating the need for joining strips. This process allows immense flexibility of operation & also ensures easy operation and maintenance. As accumulators are not required in these lines, thus making them cost effective in nature. These pickling lines are capable of producing between 200,000 to 1,000,000 Tons per annum.
Specification : Type Line of Push Pull. Hot Material Rolled M.S. Strip Thickness Strip Width Coil O.D. Coil Wt. 6.0 MM. 1250 MM. 2000 MM. 25 T. Cascade Pickling with 2 / 3/ Tanks.
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Multi Stage Rinse Cascade Hot Rinse. Pickling Medium HCL.
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GALVANISING LINES:
We offer hot-dip galvanizing lines. The lines manufactured by us are furnace type, heat to coat type or wet flux type. Efficient air-knives control the thickness of coating with great precision, either through manual settings or through automatic coat control systems. The materials can be pickled hot rolled steel, cold-rolled steel of CQ, DQ quality & full hard in nature.
Type Line
of
Wet flux. non-ox furnace.
Material
C.R. full hard.
Strip Thickness
0.6 mm. (wet flux) 1.5 mm
(furnace) Strip Width Coil O.D. 1250 mm. 1850 mm. Coil Wt. Line Speed 22 mt. 90 mpm. (wet flux) 150 mpm
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(furnace). Coating 90 - 250 gms/m2.
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ELECTROLYTIC CLEANING LINE:

Utilizing a performance enhanced, low-temperature, high volume, updraft recirculating hot air design, the Electrolytic cleaning line is ideal for refreshing steel products and other metallic mater. The Electrolytic cleaning lines are the ideal wet cleaning complement for advanced Electrolytic components.
Specification :
Type Line
of
Electrolytic Cleaning with Alkali Cold
Material
Rolled M.S.
Strip Thickness Strip Width Coil O.D. Coil Wt. Line Speed
2.5 MM.
1650 MM. 2000 MM 30 T. 200 MPM.
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ANNEALING LINE:
The demand for better annealed stainless steel has increased. Annealing is a heat-treating process conducted under controlled-atmosphere furnace to minimize oxidation, so that the product surface remains clean. It is very common for continuous annealing of strip products and stainless steels.
Type Line
of
Horizontal Tight Line.
Material
Stainless Steel.
Strip Thickness Strip Width Coil O.D. Coil Wt. Line Speed
1.5 MM.
660 MM. 1650 MM. 10 T. 30 MPM.
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ANNEALING AND PICKLING FOR STAINLESS STEEL:

The heat treatment has to be specific in annealing and pickling line to find the best compromise between strength and ductility without neglecting the surface finish. Annealing and pickling lines (APL's) are used for the treatment of hot rolled (HR) and cold rolled (CR) stainless steel strips.
HR Austenitic & CR strip is annealed and pickled continuously in an APL and HR ferric strip is only pickled. Lines for HR & CR, as well as dedicated APL's process the majority of the stainless steel production.
SLITTING LINES:
Slitting Lines have been successfully put into operation in well-known production plants & service centres. These lines have the capability to meet client's demand for minimum burr, no damage to the surface, high production capacity etc., to the fullest. The high automation level of the lines reduces the need for operator attendance and ensures economy of operation.
Characteristic Features:

High automation level to achieve high economic efficiency Minimum burr on strip edges due to high running accuracy of knife arbors
No manual interferences required as the edge scrap baller is pit mounted
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PICKLING:
In semi-continuous pickling line surface oxide layer of H.R. Coils are removed by the action of warm hydrochloric acid , which is subsequently rinsed by cold & hot water such that pickled H.R. coils does not carry any acid & is neither under or over pickled.
COLD ROLLING:
The process consists of reducing thickness of hot rolled coils to desired thickness in several passes (according to set pass schedule). This results in :-
a) Closer dimensional tolerance. b) Improved shape. c) Improved surface.
ANNEALING:
Steel after undergoing cold rolling become very hard because of work hardening & has got only limited use e.g. galvanizing because of loss of ductility. In order to restore Ductility, Formability, C.R. coils are annealed in protective Nitrogen - Hydrogen atmosphere such as to attain desired grain size and orientation. This process results in improvement in formability related properties & also in its microstructure.
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SKIN PASSING:
Skin passing of annealed cold rolled steel coils is carried out for following:
a) To suppress the yield point phenomenon which can cause stretcher strains on formed component. b) To remove the wrinkles & achieve flatness that is caused due to annealing. c) To impart matte or bright finish depending on customers requirements.
In addition to this semi-processed electrical steels are given about 7-8% critical reduction such as to improvise their magnetic properties.
SLITTING AND SHEARING:

After skin passing the coils are slit to the required width, by the precision slitting machine. The coils are further sheared to the desired length facility. The coils / sheets thus supplied to the exact sizes for end users improve the yield of CR rolled steel and sheets.
OILING AND PACKING:

The coils are provided with an uniform coating of special rust preventive oil to guard against rusting, atmospheric corrosion & to allow storage for long duration. The oil can be easily removed in normal degreasing. The coils/sheets are securely packed in bituminoid polyethylene lined Hessian and tied with steel straps to avoid any damage in handling and storage.
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CONTINUOUS PICKING LINE:

After slitting the HR coils (the basic raw material), is passed through a Continuous Pickling Line (CPL) to remove the oxides / rust or scales from the strip surface, thereby enabling further reduction of thickness to the desired level in the Cold Rolling Mills.
BATCH ANNEALING FURNANCE:

By annealing the cold rolled coils the desired properties in the finished coils are obtained by heating the material to a pre-determined temperature in a protected atmosphere and soaked for a specified time, before it is cooled to room temperature. This gives uniform properties throughout the coil and the desired microstructure of the finished product with a bright finish.
SKIN PASS MILL:

After the cold rolled coils are annealed, the strips are skin passed to improve the flatness and remove the superficial stresses over the strips. Anti-rust oil is sprayed on the strip surface for protection from rust.
COLD ROLLED COILS SLITTER:

In order to obtain uniform width throughout the coil, the edges are trimmed in the CR slitter
CUT TO LENGHT LINE:

In Cut-To-Length Line (CTL), slitted coils are sheared to the desired length as per customer's requirement with very close tolerances.
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END APPLICATIONS OF COLD ROLLED COILS/SHEETS:

Precision Tubes Bicycle / auto rims Deep / Extra deep drawn auto components for auto sector Material handling system White goods sector Furniture & office equipment
Various grades rolled along with their specifications and dimensional tolerances are detailed as under:
Material Specifications Chemical Composition (max) Hardness (VPN) UTS EL % Type C % Mn % S % P % Si % AI % Annealed MPa (GL-80) IS 513 O 0.15 0.60 0.55 0.55 - - 160-190 ----0.02- 115 Max ----- --130 Max 115-130 QH HH FH
140-160 IS 513 D -
0.12 0.50 0.40 0.40 - - 23 Min
280-420
IS 513 DD 0.10 0.45 0.035 0.035 - - 280-360 26 Min
0.06 105 Max
---
--- - -
IS 513 EDD 0.08 0.40 0.030 0.030 - - - - - 280-360 32 Min ---
0.02-0.06
95 Max
---
- -
If Grade ---
0.005 0.08 - - 280-360
0.02 0.02-0.06
95 Max
---
- -
42Min
40
IS 1079 ST-42 --- ---
0.25 - - 410-490
0.05 0.05 - - 16Min 0.60-0.90 ---
0.02-0.06
130-140
- -
IS 7226 MC-11 (C-40) 140 Max
0.35-0.45
0.04 0.04 0.15 0.35 --0.04 0.04 0.15 0.35 ---
- -
--- ---
220-280
IS 7226 MC-12(C-55) 160 Max ---
0.50-0.60
0.50-0.65 ---
- -
- - - 220-280 0.50-0.80
IS 7226 C-62 170 Max
0.57-0.67 ---
0.04 0.04 0.15 0.35 -----
- - - 250-300 0.75-0.80
IS 7226 HC-14(C-80) 180 Max ---
0.50-0.80 ---
0.04 0.04 0.10 0.35 ---
- -
- - - 270-350
HROP:-
HROP is available in all above grades .
DIMENTIONAL TOLERANCES:
Dimensional Tolerances as per BIS or any other international standard or as per customer's specifications can be supplied however closer tolerances are supplied by M/s. Avon Ispat & Power Limited. CR Strip Flattened Roller & Bush wire Offered By ACIL Offered By ACIL Thickness in mm 0.20 to 0.50 .02 Thickness in mm 0.50 to 1.15 .02 0.51 to 1.50
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.03 1.51 to 4.50 .04S Width (Slitted) in mm Up to 100 .10 Width in mm 2.20 to 5.80 5.81 to 9.00 .05 .10 100 to 200 .15 200 to 460 .20 Unslistted in mm - 6 , - Nill Length in mm Upto 500 + 2, - Nill above 500 + 3, - Nil Camber Coils 2 per Mtr Camber Coils 4 MM per Mtr
Size Range
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CR Strips
Flattened Roller & Bush Wire Surface - Bright / Rough / Matt /
Edges -Slitted /Unslitted Thickness in mm CR-0.20 to 4.30 HROP up to 6.00 0.50 to 1.15 Surface - R.P Oiled / Dieseled / With out Oil Packing - Polythene / Hessian Cloth packing is available on special demand VCI paper is also available for Coils and CTL Sheets. Width in mm 11 to 460 2.20 to 9.00 Coil ID in mm 400 and 500 400 Coil OD in mm Up to 7 kg Per mm 650 Max Length of CTL in mm 250 to 3000 Coil Width 100
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Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

FIGURE1.1- GROWTH TRAJECTORY

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

MISSION AND VALUES

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

FIGURE1.3 SCHEMATIC DRAWING OF ROLLING PROCESS

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

HOT ROLLING: The distinctive mark of hot rolling is not a crystallized

Industrial training/Bhushan Power and Steel

COLD ROLLING: Cold rolling, in the everyday sense, means rolling at

Industrial training/Bhushan Power and Steel

ROLLING PROBLEMS AND DEFECTS:

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

ADVANCED TECHNOLOGY IN SKIN PASS ROLLING:

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

USE OF LOW VOLUME LUBRICATION AND LIQUID NITROGEN :

Low-volume lubrication: Considering the fundamentals of lubrication

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

REWIND CUM TRIMMING LINE:

Industrial training/Bhushan Power and Steel

CUT TO LENGHT LINES:

3.0 MM (C.R.) 1650 MM. 2000 MM. 30 T. 30 MPM. (H.R.)

100 MPM (C.R.) 15 Cuts / Minute (H.R.). 40 Cuts / Minute 27

Industrial training/Bhushan Power and Steel

(C.R.). Sheet Length 6000 MM (H.R.)

Industrial training/Bhushan Power and Steel

COIL BUILDUP LINES:

VARNISH COATING LINES:

SKIN PASS MILL:

Industrial training/Bhushan Power and Steel

Industrial training/Bhushan Power and Steel

Multi Stage Rinse Cascade Hot Rinse. Pickling Medium HCL.

Industrial training/Bhushan Power and Steel

Wet flux. non-ox furnace.

C.R. full hard.

0.6 mm. (wet flux) 1.5 mm

Industrial training/Bhushan Power and Steel

(furnace). Coating 90 - 250 gms/m2.

Industrial training/Bhushan Power and Steel

ELECTROLYTIC CLEANING LINE:

Electrolytic Cleaning with Alkali Cold

1650 MM. 2000 MM 30 T. 200 MPM.

Industrial training/Bhushan Power and Steel

Horizontal Tight Line.

660 MM. 1650 MM. 10 T. 30 MPM.

Industrial training/Bhushan Power and Steel